1

Dear Customer, dear Reader,
On October 1 st this year it will be 10 years since Voith and Sulzer joined forces in
the field of paper technology. The new company called Voith Paper has developed
nicely and convincingly in the eyes of the pulp and paper industry. This is positively
supported by a study recently performed by an independent consultant.
In our last twogether Magazine No 15 it was reported that our business year 2001/
2002 performance was satisfactory with the exception of order intake. Since thisreport our backlog has improved considerably. Several large rebuilds were booked inaddition to 6 complete paper and board production lines.
Two new lines, one for the production of towel and the other one for super soft tissue
Hans Müller

were awarded to our Joint Venture Voith Andritz in Janesville, USA.
At this point it appears that the 10 th year of “new Voith Paper” could well develop into
one of the best ever as far as order intake is concerned.
Moving the Voith Fabrics headquarter from Raleigh, North Carolina, to the heart ofVoith’s R&D world in Baden-Württemberg underlines our efforts to grow this important unit within Voith Paper Technology through innovative products.
Our focus of growth through participating in the consolidation of suppliers to thepaper industry has been shifted to growth through innovative products and processes.
The latest testimony to this is the order we received for the Leipa mill near Berlin.
One of the fastest and widest LWC production lines using mainly recycled fibers.
We appreciate the continued support Voith Paper and Voith Fabrics receive from its
well established customer base worldwide.
“Engineered reliability” from Voith seems to pay-off.

Hans Müller
on behalf of the Voith Paper Technology team.

2

1

Another milestone in our longstanding
partnership with Langerbrugge Mill,
Belgium –Voith supplies key components
for the new PM 4 DIP plant
Voith’s long tradition of partnership with Stora Enso
Langerbrugge Mill goes back to the PM1 delivery about 70 years
ago. Almost half a century later Voith installed Langerbrugge’s
first deinking plant in 1978, followed by PM 2 in 1984 and the PM 1
rebuild in 1985/86. Several DIP capacity expansions and technological improvements in the nineties set further milestones in thisteamwork.
Herbert Gray
Fiber Systems
herbert.gray@voith.com

In the meantime Langerbrugge Mill be-

The project

longs to the Stora Enso Group. By order-

The new PM 4 newsprint line commis-

ing key components for the new PM 4

sioned in Spring this year is one ofproduction line, Stora Enso confirmed

Europe’s largest, with an annual produc-their ongoing confidence in Voith deink-tion capacity of around 400,000 tons per

ing technology and know-how.

year. The raw material is 100% recovered
paper collected mainly within a radius of

2

16/03

This is already the Stora Enso Group’s

300 km, an area where nearly 80 million

eighth Voith flotation plant in Europe.

people live.

Fiber Systems

3

Figs. 1 and 3: EcoCell pre-flotation and postflotation lines 1+2 in double-decker design.
Fig. 2: 3-D model of PM4’s EcoCell flotation
plant in Langerbrugge.
Fig. 4: EcoDirect disperger.
Fig. 5: Sami S. Pitkänen (left), L4 ProjectManager and Markus Mannström (right),
Area Manager DIP L4 Project, Stora Enso,
Langerbrugge.
3

4

Including the new PM4, the Langerbrugge

The flotation system itself principally

Voith’s contract responsibility

also in-mill now processes about 700,000 tons

comprises the cells themselves, flotation

cluded complete erection, customer per-per year of recovered paper into highpumps, internal pipework, deaeration cy-

sonnel training, and supervision of com-

grade newsprint and SC paper.

clones and walkways. A particular feature

missioning for its equipment.

from a technological point of view is theVoith’s scope of supply

system’s optimum mainstream aeration.

Contract management

The contract covered EcoCell flotation for

The disperging system, comprising two

Following a kick-off meeting at the end ofeach of two parallel pre-flotation anddispergers each with equalizing and dilu-

January 2002, erection work on the flota-

post-flotation lines. Two EcoDirect dis-tion screw, is designed for a capacity oftion plant started only six months later atperger systems are also part of the Voith

2 x 679 t / 24 h.

the end of July. One reason for this particularly fast schedule was the few but

scope of delivery.

highly efficient project meetings fordefining interfaces and handover points.

Based on a total plant capacity of 1260 t/
24h, the pre-flotation line is designed for

5

Another reason was Voith’s process and2 x 735 t/24 h and the post-flotation line

automation engineering input, which fit-for 2 x 666 t/24 h. This makes Langer-

ted perfectly into the overall engineering

brugge the biggest capacity flotation

schedule.

plant ever built by Voith for a new installation. If the cell lines had been arranged

With the support of Voith’s partner DIW

one after the other instead of in double-

Indumont, the erection work was com-decker design in parallel, the total length

pleted by Voith to the customer’s com-would have been almost as long as twoplete satisfaction within a very shortfootball fields.

space of time.

16/03

4

1

Voith Paper AS in Tranby/Norway –our Competence Center for innovative
dewatering technology
Voith Paper AS in Tranby, Norway is Voith Paper Fiber
System’s Product Center for dewatering. The company is very wellknown for its dewatering machines, such as Thune screw presses
and Thune disc filters.

Danièle Caron
Fiber Systems, Voith Paper AS,
Tranby, Norway
daniele.caron@voith.com

Backed up by quite a number of innovations over the past few years, Voith Paper
has developed into the accepted technology leader in dewatering. Development
has focussed on two main areas:● Increased capacity and efficiency for agiven size of machine and● Increased availability and lower
maintenance costs.

P ål Bendiksen
Fiber Systems, Voith Paper AS,
Tranby, Norway
paal.bendiksen@voith.com

16/03

Although these two objectives generally
need to be handled separately, whencombined they provide a true technological leap forward.

Thune presses –tradition and innovation
The history of Thune screw presses dates
back to the early 20th century. The presses became the paper industry’s standard
during the late seventies and early eighties, mainly due to their flexibility of application, compact floor space and low
maintenance costs, compared with competitor machines. In many parts of theworld the name “Thune” is synonymouswith screw presses irrespective of themake, although Thune is a Voith Paper
trade name.

Fiber Systems

5Fig. 1: Knock-off of the pulp mat from retrofitted Bagless discs in a disc filter installed in an
OCC line.
Fig. 2: Typical Thune screw press installation ina deinking plant.
2

The fundamental principle of screws (andscrew presses) was described more than2000 years ago by Archimedes. One canregard it as a simple machine, with justone moving part – the screw itself(Fig. 3). There is, however, a wide range
of design-related parameters directly or
indirectly influencing the overall operation of the press. Much of our recent research work has focussed on optimizingpress design, while still maintaining thelow power consumption of the original
design.
This work has, for instance, resulted in
an improved screw geometry called
HiCap (Fig. 4). Every screw press has acustomised design, optimised for eachcustomer’s specific operating conditions.

Depending on press size, the improved
geometry can provide up to 40% higher
capacity, with increased outlet consistency and reduced power consumption at
the same time.
The fact that the press screw alone accounts for these improvements means
existing presses can be upgraded. Suchupgrades are becoming increasingly popular since mills can improve overall efficiency and increase production beyond
the original design capacity of their systems. Significant capacity increases canthus be achieved without the substantial
investments normally required. Fig. 5
shows the improvements by upgrading
the dewatering of TMP rejects in a Norwegian mill.

Increased availability andreduced maintenance costs
The operating principle of a screw press
requires a certain amount of friction inorder to form a solid plug in the outlet
zone of the press. This friction inevitably
leads to wear of the static parts, but especially the moving parts of the press.
The screw flight is most affected and has
to be rewelded at certain intervals depending on stock characteristics.
For very abrasive types of stock, thistime-consuming rewelding proceduremight have to be repeated as often as
every four months, leading to substantial
downtimes and high maintenance costs.

16/03

6

Fig. 3: Design of the Thune screw press(standard version).
Fig. 4: The new HiCap- (High Capacity) screw.
Fig. 5: Comparison of operating data before andafter installing a HiCap screw in an existing screwpress.
Fig. 6: Wearless segments for increasing the lifeof screw flights.
3
Inlet

Removable cover
Dewatering zone

Compression zone

Steel
frame
Screen basket

Screw shaft

Filtrate vat

Outlet4

Before After

5
Freeness (CSF)
Temperature (°C)
Production (t / 24 h)Outlet consistency (%)
Speed (min -1 )(Fixed speed drive)

6

400
70
75
35-39
42

400
70
130
35-40
42

2 countersunk screws

Segment withhard facing
Fixing plate

In order to provide a more efficient solution, Voith Paper has developed theWearless segments which are attached tothe screw flight by a patented method
ensuring they not come loose (Fig. 6).
A wide range of wear surfaces were tested. Ceramics have proven to be the bestmaterial in terms of wear resistance but
have the disadvantage of being brittle andsusceptible to breakage if subjected topointed or abrupt forces. Sintered hardfacing has so far proven to be the bestcompromise between wear resistance andmechanical strength, but traditional hardfacing is also available.
By upgrading presses with Wearlesstechnology, the intervals between screw
flight resurfacing have increased by afactor of up to 6, and the shutdown timerequired to do the job is reduced by a

16/03

factor of up to 10. This technology therefore provides a dramatically improved
availability.

Recent improvements in discfilter technology
One very important technological breakthrough for Voith Paper AS was thelaunching of the “Bagless” technology.
Conventional filter bags are no longer required. This patented special profiling of
the disc filter sectors significantly reduces shutdowns and the costs for wear
material.
The Bagless sector (Fig. 7) consists of
two corrugated stainless steel plates witha fine perforation. The plates act as thefiltering media. This technology offers an

Fiber Systems

7

Fig. 7: Bagless sector
with close-up view.
Fig. 8: Comparison ofdisc filter speed before
and after installing Baglessdiscs in a disc filter at
UPM-Kymmene, Shotton,
Great Britain.

78Filter speed (min-1)

Shut down for installation of Bagless discs

1.0

0.5

08.08.2001

Lower speed despite a substantial increase in filter capacity
Conventional Discs

even higher specific filtering capacity per
area, compared with conventional filterbags. This means no more shutdowns for
replacing worn bags, thus saving bothtime and money. In addition, mills avoid
the risk of a higher fiber content in thefiltrate when bags are damaged. Plastic
bag trash is also eliminated.

From pilot plant to industrial
scale
The development of the new Bagless sectors began in our pilot plant in Tranby,
Norway where these new corrugated sectors were extensively tested on our pilot
disc filter. While providing the same filtrate qualities as conventional discs, thefirst trials showed very promising resultsfor higher capacity as well as a high pulp
mat consistency.
Several discs were trial run in various paper mills and the first complete retrofit
was undertaken at SCA Obbola, Sweden
in December 1999. A disc filter was upgraded with new filtrate valves, centre
shaft and all discs were replaced by Bagless discs. The disc filter dewaters OCC
stock in a long fiber line and has beenrunning to full satisfaction since start-up

08.10.2001

Bagless Discs

three years ago. A higher capacity and an
excellent finished stock consistency havebeen achieved.
The next retrofits were two Thune discfilters dewatering ONP/OMG stock at
UPM-Kymmene, Shotton, Great Britain.
These were originally delivered with conventional discs in 1998. This was thebest opportunity to obtain a mill comparison between conventional and Baglessdiscs. All the conventional discs were
replaced by Bagless in both loops. We
installed 10% fewer discs in both filters
compared with the original filters withconventional discs. The results wereastonishing (Fig. 8). The filter speed
in Loop 1 dropped from 1.25 min -1 to
0.65 min -1, yet the filtration capacity perdisc increased significantly!
Fig. 8 shows the trend line from the DCS
showing the filter speed for a period of
two months. Similar results were obtained for the filter in Loop 2. The speed
was so low that the pulp mat was thickand substantially dry and filtrate quality
had improved considerably. Even when a
few discs were removed the filter could
still handle the flow. Two years after the
installation of Bagless discs at Shotton,
the mill remains very satisfied with the results.

Improved filtrate quality
The major concern from paper mills is
the size of the perforation, which is obviously bigger than with conventional bags.
In the dewatering cycle the perforated
plates or bags provide the filtering media
only during the first few seconds. As
soon as a pulp mat starts to form, thepulp mat itself becomes the filtering
medium, not the plates or bags. The pulp
mat has a much smaller open area than aconventional bag.
Another successful installation was the
upgrading of a saveall filter to Bagless at
International Paper in Saillat, France. The
filter runs very slowly since the Baglessdiscs were installed in May 2002. Despite
the high ash content, the quality of theclear and superclear filtrates is now evenhigher. Philippe Benoiton, Saillat’s paper
machine superintendent, commented asfollows: “We are never restricted by thecapacity of the filter and at the sametime, the filtrate quality has significantly
improved. This is a great success.”
Smaller disc filters
At this point in time we were still very
conservative in selecting the machine

16/03

8

9

Fig. 9: Typical Thune disc filter installation.
Fig. 10: Design of the Thune disc filter.

10

Cloudyfiltrate Clear
filtrate

Inlet

Outlet16/03

sizes, despite the significant increase incapacity provided by Bagless discs. In
fact, with Bagless, smaller disc filters canbe installed to handle the capacity incomparison with conventional bag filters.
In other words, Bagless filters save mills
space and money.

strength stocks. Four installations inNorth America handle TMP stock, while
recycled/kraft stocks are the focus for installations in Europe and Asia. Nine Dragons in China bought a saveall filter with
Bagless discs two years ago. They wereso satisfied that they bought ten more
Bagless disc filters at the end of 2002.

Future disc filter installations

After every start-up the results have surpassed our expectations and customers
are fully satisfied. Our research and development work on Bagless discs continues so that we can offer our customers
even more efficient Bagless technology,
including their suitability for upgrading
competitors’ disc filters. The overall aim
is to increase manufacturing process efficiency.

Following these successful installations,more disc filters are being sold with Bagless discs than with conventional ones. It
is now Voith’s standard feature unless, ofcourse, a customer specifically requests
conventional discs. As of today, 33 complete installations with Bagless discs
have been sold worldwide, on a total
market size of some 160 filters. Elevenfilters are already in operation, running
as dewatering or saveall filters, handling
TMP, ONP / OMG, Kraft, OCC and wet

Voith Paper is confident that Thune Bagless discs will be the trendsetter for discfilter technology in the future.

Paper Machines

9

LEIPA-Schwedt PM 4 –large order finalized
On May 15, in Voith’s historic “Eisenhof” residence, the
LEIPA Georg Leinfelder GmbH management board under Dr. Hubert
Schrödinger signed a large order worth about 150 million Euro forthe new Voith Paper machine No. 4 in Schwedt.

Klaus Siebert
Paper Machines Graphic
klaus.siebert@voith.com

The PM 4 line is designed for producing

cessing, from recovered furnish handling

300,000 t.p.a. of coated magazin paper in

to finished paper roll packaging.

the basis weight range of 39 to 60 g/m 2
from 70% to 100% deinked recovered pa-“LEIPA-Schwedt PM 4 sets the bench-per. The wire width will be 8,900 mm, themark for production by partnership”,

maximum production speed 1,800 m/min.

says Voith AG Board Chairman Dr. HansPeter Sollinger. “This line is based on

Purpose of this new line is the large-

our new PLP (Process Line Package)

scale production of standard LWC in con-concept, whereby we take over responsi-

sistently good quality and in any desired

bility for the entire production line andquantity, even at short notice. To meetguarantee our customers exactly the end

this specification, Voith developed aproduct they require. In our role as sys-

cost-effective, custom tailored produc-

tem partner, we team up with the cus-tion line concept for seamless A-Z pro-tomer from beginning to end – including
1

Fig. 1: The LEIPA Georg Leinfelder GmbHand Voith Paper management delegations after
contract signing.

16/03

10

Fig. 2: Harry Hackl signs the contract.
Fig. 3: Dr. Hubert Schrödinger signing thecontract.
Fig. 4: Konrad Göbel talking with Kurt Brandauer.
Fig. 5: Impression of the new production line
(blue) in Schwedt.
Fig. 6: Schematic layout of PM 4.
2

3

4

process engineering – until all joint tar-product developments, production costs

incorporated in this new PM 4 line is thegets have been met.”

and services.

state-of-the-art TopDuoRun drying tech-This system partnership does not stop

Voith is supplying all machinery andthen either. Years after going on line,

equipment for LEIPA-Schwedt PM 4, asContactless tail pick-up from the last dry-

Voith Paper still keeps the customer fully

well as stock preparation line engineer-er cylinder, together with proven Fibron

competitive with state-of-the-art produc-

ing for 780 t/day of recovered paper. The

vacuum technology and high pressuretion line reliability and product quality.

machinery mainly comprises a twin-drumwater jet cutters, ensure optimal tailpulper, screens and dispergers, and thetransfer.

nology.

“Quality Tons on the Reel” means maxi-

flotation units. Also included in the scope

mizing the cost-effectiveness of paperof supply are the components for recov-

The base paper is precalendered in an

and board production lines. Optimal

ered paper dewatering, pulp and furnish

EcoSoft Delta calender prior to coating.

availability at maximum efficiency, opti-

charging, bale dewiring and rejects han-The heart of the online coater is a Speed-

mal utilization of all furnish and otherdling. Apart from the recovered paper

Sizer, which simultaneously coats bothmaterials with consistently high productstock preparation line, delivery also in-side of the sheet at 8 g/m 2. Automatedquality – these are the criteria for prof-

cludes a 150 t/day chemical pulp prepa-

coating thickness control (Profilmatic C)

itability. The One Platform Concept

ration line. The approach flow section in-in machine and cross-machine directions

puts this Voith Paper philosophy into

corporates cleaners, screens, whitewater

ensures maximum process stability. The

practice. By taking account of the entire

tower and pumps.

highly efficient coating line air drying

papermaking process from furnish to end

system also ensures optimal web stabili-

product, it ensures optimally cost-effec-

First class formation is ensured by thetive production lines for all kinds of pa-

DuoFormer TQv vertical former togeth-

per and board. And it takes into accounter with a ModuleJet headbox with dilu-

not only the papermaking process com-tion water control, the predominant head-ponents, but also the production line life

box in the paper industry. The Tandem

cycle. From the beginning, the One Plat-

NipcoFlex press ensures maximum dryform Concept thus takes full account ofcontent and optimal paper quality. Also

16/03

11

5

ty. An 10-roll Janus MK 2 calender, in-Top slitters with flying splice, automatic

Site construction work started on April 1,

stalled online, meets the requirement for

knife

roll

2003. Erection will commence on March

this LWC paper for excellent printabilitychange are designed for finished rolls,

1, 2004, with commissioning scheduled

by ensuring high gloss and smoothness.

weighing ten tons each.

to begin on August 18, 2004 and produc-

The Sirius slitter-winder system for

Voith is also supplying the entire PM

winding paper rolls up to 3,500 mm dia.

automation system including comprehen-

LEIPA Georg Leinfelder GmbH, owned byat speeds up to 2,000 m/min, is a trend-

sive cross-profile control and Enviro-

the Schrödinger family, was foundedsetting innovative development meeting

Scan

Voith

more than 150 years ago. In 1992 LEIPA

the highest roll quality demands by im-

Machine Monitoring System gives early

took over the former papermaking coop-plementing state-of-the-art winding tech-warning of any bearing damage or othererative VEB Papier & Karton, Schwedt an

nology.

problems. The scope of supply also

der Oder, and expanded this mill into thepositioning

andautomatiction startup on August 31, 2004.

moisturecontrol.

The

includes web inspection system, sheet

company’s second largest after the tradi-

Only one operator crew is required forbreak analysis system, and the approachtional headquarters in Schrobenhausen,

the entire winding line – comprising full

flow section measurement and analysis

Upper Bavaria. The Schwedt mill pro-paper roll handling, two VariTop slitters,

systems. During the design phase Voith

duces uncoated and coated board, graph-a VariFlex rewinder and a Twister

will also be responsible for all the detail

ic LWC papers, and corrugated carton in

2-line roll packaging machine – because

engineering for the automation of thebrown and white grades. Annual output

the roll slitters and roll packaging ma-

paper machine including peripherals andcurrently totals around 420,000 metricchine are fully automated. The two Vari-stock preparation line.

tons.

6

16/03

12

Order Package from Stora Enso
for major rebuilds in Finland and Germany
On November 15, 2002, Voith Paper was awarded two
major rebuild orders by Stora Enso with a handshake, one major
rebuild of the BM 3 for Stora Enso Packaging Boards at the
Baienfurt mill, Germany, and another major rebuild of PM 3 inVeitsiluoto, Finland. Stora Enso is among the world’s leading
forest industry concerns, with 43,000 employees in 40 countries,
a production capacity of 15 million tons of paper and board, andReinhard Wilthaner

annual sales of 13.5 billion Euro.

Paper Machines
Board and Packaging
reinhard.wilthaner@voith.com

Baienfurt BM 3

Johannes Rimpf
Paper Machines Graphic
johannes.rimpf@voith.com

By officially signing the contract on November 25, 2002, Stora Enso and Voith
sealed their cooperation for the major rebuild of BM 3 in the Baienfurt mill. The
board machine was originally supplied byVoith in 1970 and rebuilt several times in
the past. The BM 3, with a wire width of
5,150 mm, an untrimmed width at thereel of 4,760 mm and a design speed of
850 m/min, produces board in a basis
weight range of 160-380 g/m 2. Currently,
the Baienfurt mill is producing 175,000
tons/year of high-quality coated board
from virgin fibers for packaging, cigaretteboxes and graphic applications.
The rebuild is a crucial challenge of the“Mission 2004”, an investment project by
Stora Enso Baienfurt to strengthen the location and the competitive situation. By

Jukka Paananen
Paper Machines Graphic
jukka.paananen@voith.com

16/03

boosting production to 210,000 tons/year,
while enhancing the quality of the end
product, Stora Enso Baienfurt will be optimally prepared for the future and continue to hold its leading position in thefield of board production. The rebuild will
also influence positively the accessibility
and operability of the machine.

Time schedule
It is the mutually agreed upon goal tocomplete the rebuild in the shortest timepossible. In mid-November 2003, the firstpre-assembly work on site will start while
the board machine is running. In early
January 2004, the board machine will beshut down to carry out the rebuild. Within three and a half weeks between shutdown and restart, the major rebuild will
be completed in early February.

131Main activities andcomponents
The scope of supply includes the rebuildof the entire press section. The firstpress will be double-felted. The secondpress will be upgraded into a double-felted NipcoFlex shoe press for gentle
drainage, while preserving bulk, and thethird press will be rebuilt into an unfeltedsmoothing press (offset press) with newroll covers.
In the pre-dryer section, a new firstdryer group and a fifth dryer group will
be installed. The first after-dryer groupwill be designed as a three-tier dryer
group ,followed by sweat dryers. The drying efficiency will be optimized by additional measures, such as the rebuild of
the steam and condensate system, the installation of stationary siphons and blow
boxes.
A special “highlight” of the rebuild in
Baienfurt will be the introduction of the
NipcoFlex shoe calender technology,
which is a new development by Voith
Paper. The calender has a very wide nip(up to 250 mm) and can be operated attemperatures above 250° C. Under theseproduction conditions, the board quality
in terms of bulk, stiffness, smoothness
and printability can be significantly improved. The new NipcoFlex calender willallow the existing Yankee dryer to be removed later on, resulting in additional
potential for increasing speed and output.
In the coater, the coating sequence will
be modified according to the latest
knowledge, and the coating equipment
will be rearranged. The drying efficiency
will be increased by installing two new
Krieger hot air dryers, with the existingIR dryers being re-used. After the rebuild, non-contact web guiding and drying will be ensured, and, to achieve ahigher safety level, a two rope tail threading systems will be installed.
For wind-up, the Sirius system with centerwinds and reel spool magazine will be
used, allowing parent rolls of 3,500 mm
diameter to be wound. The parent rolls
are transported to the unwind of thewinder by a transport cart with a turning
device, the empty reel spools are returned fully automatically to the Sirius
magazine.
The web transfer in the entire machine
will be optimized, using Fibron systems
and a rope system from the second afterdryer group to the Sirius reel. The scopeof supply also includes the pertinent ancillary units as well as the complete hydraulic, pneumatic and electrical control
systems, engineering, personnel training,
installation and supervision of start-up.

Helmut Endler
Project Manager
of Mission 2004
at Stora Enso,
Baienfurt“Voith is known to be a reliable andinnovative supplier of technology.
For this project, Voith was chosen as
the supplier because of the excellent
performance characteristics, flexible
project handling and rapid completionof the rebuild. In addition, the BM 3 isbest known to them, and so we areconvinced Voith is the ideal partner forthe rebuild.”

Fig. 1: Stora Enso, plant Baienfurt, Germany.
Fig. 2: Scheme BM 3.

2

16/03

14

3

Veitsiluoto PM 3 –Voith leadership in Finland
as well
Close teamwork on this project started
even before placing the order on November 15, 2002 at the Stora Enso headquarters in Stockholm – for a paper machine
rebuild at the world’s most northerly millnear Kemi in Finland. A good many suppliers had repeatedly upgraded PM 3 inVeitsiluoto to the latest state of technology, but now practically the wholemachine was to be replaced with newcomponents. A challenging task for achallenging customer – “We’re not only
the most northerly customer for paper
machine suppliers, but also the most difficult!”
The technical data of this “northernlights” paper machine can be summarized
as follows:● Product range:
woodfree envelope paper 70-130 g/m 2,
woodfree copy paper
75-100 g/m 2● Wire width 7,180 mm● Operating speed 1,200 m/min● Output 912 t / 24 h

4

16/03

This rebuild includes installation of a new
dilution water line, with wet end controller for high runnability and improved
paper quality, and retention control for
better CD and MD profiles. To minimize
sheet breaks, the basis weight is monitored throughout the wet section as afunction of stock consistencies, flows
and machine data. This enables settings
to be optimized for best possible operating conditions at all times.
The MasterJet F headbox with ModuleJet ensures optimal basis weight distribution and fiber orientation. Thanks to
the Profilmatic M control concept, CD
profiles are consistently excellent, whilelamellas in the nozzle improve turbulence
characteristics to further optimize thepaper structure.
A new fourdrinier section with DuoFormer D makes for good formation withminimum 2-sidedness and high drainage
capacity. More than 200 formers of thistype are now in well-proven service
worldwide.
Thanks to a DuoCentriNipcoFlex press
incorporated in the rebuilt PM 3, high dry

content will be attained at good volume.
This is the eleventh shoe press sold by
Voith in Finland, and the entire press will
be installed on steel foundations also
supplied by Voith. Integrated in the press
section is a steam blow box with Profilmatic S control system for consistently good moisture CD profile.
An EnviroScan right at the beginning of
the dryer section displays the moistureprofile after the press, and enables a
short control loop to the steam blow box.
Ropeless tail transfer ensures optimal
web run through the entire dryer section,
while DuoStabilizers make for improved
shrinkage behaviour and narrower margins. Felt and wire changing devices, tominimize shut-down times, are also included. All the drying cylinders have to
be overhauled, and this alone is a logistical challenge. The existing IR dryer
before the afterdryer section is being
extended to include an additional nozzle
stabilizer.
Tail pick-up between the pre and afterdryer sections and between the after
dryer section and the reel is performedby 8 Fibron VTT3000 belts all in all.

Paper Machines

15

5

These ensure smooth transfer at all
times, irrespective of basis weight andoperating speed. The new Fibron belt
technology, with drum motor in a belt
turning roll and integrated vacuum generation by compressed air, saves space andminimizes maintenancetime.

a solid core structure, thanks to variable
line force control in the primary and secondary zones. Empty reels are fed from afully automated magazine system. Together with the “goose neck” system, thisensures optimally dependable web transfer to the next empty reelspool.

The online 2-roll EcoSoft-Delta calender belongs to the latest Voith soft calender generation. Based on the successful
Janus MK 2 principle, this type of calender with its 45° frame layout ensures
quiet, smooth-running operation, free ofvibrations. Fine sheet profiling is takenover by a plastic coated Nipcorect roll.
An innovative feature of this calender is
its swivelling dual console, on which allroll related elements are mounted, suchas guiding devices, etc. For roll changing,the dual console is simply swung away togive direct access to the 45° roll stack.
This eliminates the substantial time spentpreviously for removing and re-installingthe components hindering the access.

The scope of supply also includes a VariFlex M two-drum winder with a working
width of 6,500 mm and maximum operating speed of 2,500 m/min. This new slitter-winder (for copy and fine papers) is astate-of-the-art machine with buttsplicer, automated knife positioning system, automatic paper roll change andgraphical user interface. The two winder
drums – the first of which with wellproven MultiDrive coating, the second
with tungsten carbide coating – work in
conjunction with a specially coated feedroll to ensure optimal winding results.

Incorporated in the end section is a highly sophisticated TR 125 reel. This reelenables consistent winding by generating

Also included in the scope of supply areother components and units required for
paper machine operation such as: central
oil lubrication system, mechanical drives,
machine air technology system with newhood, pulper, and conveyor belts.

Since the agreed standstill time is very
short for a project of this magnitude,
smooth coordination of all rebuild measures is extremely important. Only
53 days are available from paper topaper. To comply with this, perfectly
planned and organized erection and commissioning are essential – as well as
optimal logistics: about 6,000 tonnes ofmaterials are required for this rebuild.
Thanks to a newly developed spare parts
catalogue system, the customer can select all spare part components easily andrapidly. Paper machine components selected from a drawing or parts list on themonitor are electronically deposited in a
“shopping basket” which can be called up
from Voith at any time by e-mail.
It was due to the customer’s confidence
in our “Engineered Reliability” that
Voith was chosen for this rebuild. Our
combination of carefully matched andwell-tried components with outstanding
innovation made Voith the preferred supplier both for the Veitsiluoto and Baienfurt rebuilds (both were ordered together). And already after a very short time, aperfectly harmonized project team has
been formed between Stora Enso andVoith.

Fig. 3: Stora Enso, Veitsiluoto mill, Finland.
Fig. 4: Layout of the PM 3 rebuild.
Fig. 5: Contract signing at Voith headquarter,
Heidenheim, Germany.

16/03

16

Varel paper and board mill –new paper machine increases production capacities
In mid-May 2003, the paper and board mill Varel GmbH & Co KG in Varel,
Germany, placed an order with Voith Paper for the supply of the new paper machine
PM 5 for the production of testliner and corrugating medium.

Together with the new PM 5, the Varel
paper and board mill will operate in future two paper machines for the production of corrugated board papers and twoboard machines, using 100% secondary
fibers as raw material. At present, the capacity of the mill in Varel is 400,000 tons
per year, with approx. 230,000 tons per
year accounting for packaging papers and
170,000 tons per year for board. This investment is made by the Varel paper andboard mill to increase its total capacities
to more than 650,000 tons/year and tomeet their customers’ particular demands
even better in the future.
The paper machine has a wire width of
6,250 mm and will produce papers within
the basis-weight range of 70-120 (150) g/m2.
The design speed of the machine is
1,300 m/min. It is laid out for a grossproduction capacity of 850 metric tons/
per day.
From the headbox to the winder, all components will be supplied by Voith and are
integrated in the One Platform Concept.

16/03

For this machine, Voith will equip theforming section with a DuoFormer
Base, including a two-layer MasterJet
headbox and a ModuleJet dilution-water
control system for the back layer. In
combination with the gap-former technology used, optimum CD profiles andstrength properties will thus be achieved,
while ensuring an economical use of raw
materials.
The use of the DuoCentri NipcoFlex
shoe press ensures excellent runnability
and high dryness.
In the CombiDuoRun dryer section, thefirst three dryer groups are single-tier,while the remaining pre-dryer section isof two-tier design. The after-dryer section consists of two single-tier dryer
groups and one two-tier dryer group. In
addition to other Voith components,
Fibron systems and DuoStabilizers
will also be used in the dryer section.
A SpeedSizer application unit ensuresuniform and trouble-free film application.

The MasterReel with linear-load measurement ensures optimum parent rollbuild-up with best winding quality. At theend of the process, a VariFlex M winder
is also part of the advanced process technology.
Both partners agreed that the complete
erection and start-up supervision as wellas the project engineering for the paper
machine will be carried out by Voith.
In addition to the technological competence and the convincing concept ofVoith, the long-standing partnershipbased on trust between the Varel paperand board mill and Voith was anotherreason for placing the order with Voith.
Apart from other rebuilds, Voith had supplied the worldwide first tandem NipcoFlex press for the production of board to
Varel.

Fig.: Varel paper and board mill, Germany.

Paper Machines

17

Emin Leydier, France –new production line for testliner and corrugating
mediumIn early May 2003, French paper manufacturer Emin Leydier
placed an order with Voith for the delivery of the new production line PM 1
for testliner and corrugating medium. The large-scale project concerns toa greenfield mill, which will be built at Nogent-sur-Seine, France.
1

2

Fig. 1: Les Papeteries
Emin Leydier in Champblain/
Laveyron (Drôme), France.
Fig. 2: From left to right: Rudolf
Estermann, Thomas Volkinsfeld,
Voith Paper, Hugues Leydier,
General manager of Les Papeteries
Emin Leydier, Philippe Leydier,
Chairman of Emin Leydier Group,
Jean-Louis Leydier, project
manager of the new plant.

The family owned company Emin Leydier
was founded in 1975. The company’s
headquarters are now located in Lyon,
France. Currently nearly 500,000 tons ofpaper for corrugated materials based onrecycled fibers are produced annually.
Emin Leydier is a company especiallycommitted to the environment. Choosing
the advanced Voith process technology
proves that this technology manages tocombine the crucial quality parametersand productivity features with the highest
environmental standards.

1,500 m/min. With an output of up to
1,000 tons/day, Emin Leydier will extend
its position as one of Europe’s leading
packaging paper manufacturers.

Emin Leydier also produces corrugatedpackaging in four plants in France andone in Italy (170,000 tons per year of
corrugated board). Moreover, the company is investing in a new plan – elytra – inthe west of France, which will produce
food contact packaging.

The complete package contract for thefiber processing line, which will handle
100 % recovered paper, focuses on thebest possible stock cleanliness and development of the furnish strength potential to satisfy the high quality demands ofthe final product.

The process
The PM 1, having a wire width of 6,050 mm,
will produce top-quality testliner and corrugating medium in a basis weight rangeof 70 -110 g/m 2. Its design speed will be

Emin Leydier ordered the entire process
technology from Voith, which underscores the particular process competences of the supplier. The production
line has been well defined according to
the successful One Platform Concept,
from the stock preparation system to thefinishing equipment.

Voith’s Wet End Process, linking thestock preparation with the paper machine, provides a number of significant
advantages for the papermaker, including
optimum stock homogeneity, pulsation
minimization and a more than 50% reduction in system volume. The result isenhanced sheet profiling.

The paper machine is designed according
to Voith’s latest technology. This advanced design combined with the extensive experience with secondary fiber
treatment and high speed packaging
paper machines will allow an optimized
production process in terms of quality ofthe end product and economic efficiencyof the production line.
Voith Paper Automation supplies anextensive package. In addition, Voith will
be responsible for the supervision of installation and start-up and for the basic
engineering. Special focus is put on several training phases for operating andmaintenance personnel to ensure asmooth start up.
A Variflex M winder is used to slit all parent rolls coming from the PM 1 into finished rolls. To be able to handle the PM 1
production, winder is designed for an
operating speed of 2,500 m/min and fully
automated – flying splice unwind, fully
automatic slitter positioning system,
automatic finished roll change system,
etc. For reasons of noise protection andsafety, the VariFlex is of completely enclosed design.

16/03

18

Fifth SC line ordered from Voith –Maxau PM 6

At the end of March 2003, Voith Paper received the order
Karl-Heinz Bühner

from Stora Enso Maxau GmbH & Co. KG, Germany, for rebuilding

Paper Machines Graphic
karl-heinz.buehner@voith.com

and modernizing the PM 6 at Maxau.

This is the fifth SC paper production line

Based on the One Platform Concept, thehighest wound paper roll quality, and, by

to be ordered since 1998 in Europe and

new PM 6 was designed in close team-upgrading the existing VariTop slitter, it

America – all of which from Voith. The

work with Stora Enso to meet future mar-will be possible in future to meet modern

total capacity of all these installations is

ket demands. This 8,100 mm wide paper

printing machine needs for large paper

1,160,000 t.p.a.

machine will produce SC-B grades in therolls up to 4,300 mm diameter.

basis weight range 45-56
As already in Ettringen, Schongau, Donna-

g/m 2

at a
The scope of delivery also includes new

design speed of 2,000 m/min.

approach flow section equipment, com-cona and Laakirchen, Voith received the
Maxau order against very stiff competi-

The new PM 6 line mainly comprise apletetion. Stora Enso’s confidence in our

DuoFormer TQv, a vertical former with

automation and overall process responsi-

trend-setting SC production technology

excellentbility.

once again confirmed Voith’s market

ModuleJet headbox with dilution waterleadership in this sector.

control, the most widely used headbox in

A system partnership for two years has

the paper industry, a DuoCentri-Nipco-also been agreed between Stora Enso andThis almost complete new production line

Flex press section with separate fourth

Voith. During this time new goals, going

replaces the 35 year old Voith PM 6 inpress for highest dry content and best

well beyond the contractual targets, will

the same building with an output of

paper quality with minimal 2-sidedness,be set for productivity, paper quality and

140,000 t.p.a. The new PM is designed

and the advanced TopDuoRun drying

product adaptation.

for a production capacity of 260,000 t.p.a.

technology.

formation

performanceandengineering,

complete

erection,

After a very short “paper to paper” shut-and will improve the customer’s competitive standing thanks to higher produc-

Another highlight is the Janus MK 2 on-

down time of only 65 days, commission-

tivity. Plant expansion plans envisageline calender which with its divided stacking of the rebuilt PM 6 is planned forincreasing the output of this line evenof 2 x 5 rolls, including cooling rolls,

September 2004.

further to 280,000 t.p.a. The furnish used

gives optimal results with less blackening

will mainly be deinked pulp and bleachedand greater flexibility. The Sirius reelgroundwood.

system ensures minimal paper losses and

16/03

19

1

Rauma PM 1 –rebuild for high speed PM

UPM Kymmene is one of the leading producers of magazine papers and produces on 25 paper machines in 7 countries
worldwide. At the Rauma location, UPM Kymmene operates atpresent 4 paper machines; 2 machines each for SC papers and for
LWC papers. With 1,200 employees and a production capacity of
1,160,000 metric tons per year, the Rauma paper mill is now theworldwide largest production location for magazine papers.
Wolfram Sturm
Paper Machines Graphic
wolfram.sturm@voith.com

Newsprint and coated/uncoated fine papers are produced in otherdivisions. Magazine papers are used for magazines, catalogs andadvertising brochures. There is an increasing demand worldwide
in this sector.

16/03

20

Yngve
Lindström
Director LWC
Production Unit
UPM Kymmene

Rauma is located in the South West of
Finland directly at the Baltic Sea. Rauma
is known for 3 things: its nice old town
center, the production of lace and its
special dialect. The old town center is
one of the 4 places in Finland selected by
the UNESCO as world cultural heritage.
Today the town, founded in 1442 andwith a population of 38,000, is characterized by industry, above all in the field of
pulp and paper production.

Objectives of the rebuild“The professional and innovative
handling shown by Voith for the Rauma
100 project was very impressive to us.
We are very satisfied with the progressof the entire project and the excellent
restarting of the machine. The cooperation with Voith and the support which
we were given during the project andare still given are excellent. We are very
confident that we will reach the rebuild
objectives within a very short period
and that we might even surpass themin some areas.”

Wood-containing, coated papers for offset and rotogravure printing in the basisweight range from 57 to 80 g/m 2 are produced on PM 1. The trim width of themachine is 8,150 mm.
PM 1 was originally started up in theeighties and rebuilt at the end of thenineties in the online coater and wet-end
sections. The new rebuild should further
improve the runnability and productivityof the machine.
After the evaluation of intensive technicaland technological studies, Voith was selected as the supplier of the papermachine rebuild. Considering the existingmachine configuration and the targeted
production speed, Voith definitely favoreda rebuild of the third press into a DuoCentri NipcoFlex shoe press and thereplacement of the fourth press withdryers.
The design of the press concept was themain reason that it took the customer
longer than expected to decide on the rebuild and on the supplier. Technological

16/03

and commercial aspects had to beweighed up carefully. The rebuild concept
was supposed to be state of the art, therebuild time should be as short as possible and the paper machine should berestarted as smoothly as possible. Proper
referencesproved that the solution suggested by Voith would meet the customer’s expectations in every respect.
It is now state of the art to place the NipcoFlex press ahead of the open draw, toequip the dryer section with ProReleaseboxes and DuoStabilizers and to operate
the entire dryer section without ropes.
UPM Kymmene Rauma wanted to reach,above all, an increase in production
speed at constant efficiency as well as a
reduction in the use of pulp. This wasachieved by the higher dryness after thepress and the resulting higher strength of
the wet paper.

The project
The rebuild suggested by Voith will improve the runnability and efficiency of themachine and will also have a positive effect on the process in the paper machine.
Results from trials with comparable pro-

Paper Machines

21

Fig. 1: Rauma PM 1.
Fig. 2: At the rebuild.
Fig. 3: Kari Piipponen and Yngve Lindström.
Fig. 4: Scheme of PM 1.
2

3

duction lines – with and without a fourthpress – have helped to substantiate thisconcept. It is important to produce theend product – coated, wood-containing
papers – at improved quality in future.
The entire rebuild is based on known andproven components and a concept, similar to what was installed in other recent
rebuilds.The time between order placement and installation was extremely
short. Already prior to the order placement, the future project team was selected and familiarized with certain partial areas. This guaranteed the short delivery
time for the entire rebuild.

The cooperation with the customer was
objective-oriented and based on partnership relations. Voith’s experience withsimilar rebuilds and the customer’s assistance for certain work made thesmooth completion of the rebuild possible. Detailed planning was required inorder to coordinate all activities to be
performed during the short shutdown of
21 days from paper to paper and to ensure the timely restarting. Voith completed this phase two days earlier thanplanned. Already 10 months after orderplacement, the first parts were supplied
for pre-assembly and after only 12 months,
the machine was restarted.

In a first statement, the project work andthe performance during erection andstart-up were highly praised. The Rauma
team was already familiar with the operation of the machine after a few weeks sothat normal operation of the machine waspossible very soon after the rebuild.
Today it can be stated that the main rebuild objectives were already reached a
few weeks after the start of the machine.
The goals set by the customer in thestart-up curve concerning production andefficiency have already been exceeded.
Voith will continue to cooperate with thecustomer in optimizing the paper machine to reach the ambitious goals.

4

16/03

22

Aracruz Celulose
inaugurates Fabrica C and starts to produce
2 million t onnes of pulp per year
Aracruz Celulose, Brazil, world leader in the production
Flavio Silva
Voith São Paulo, Brazil
flavio.silva@voith.com

Luis Fernando
Porchia
Voith São Paulo, Brazil
luis.porchia@voith.com

16/03

of bleached pulp from eucalyptus, inaugurated its third operating
unit, Fabrica C, on August 2nd, 2002. This unit will increase pulp
production from 1.3 million to 2 million air dry metric tons per year.

The Fabrica C inauguration took place inthe city of Aracruz, State of Espírito Santo, Brazil. Among the several authorities
that attended the event, were: His Excellency Mr. Fernando Henrique Cardoso,
President of the Federative Republic of
Brazil; Mr. Erling Lorentzen, President ofAracruz Board of Directors and one of themain company shareholders; Mr. Antônio
Ermírio de Moraes, shareholder of the
Aracruz Celulose company and memberof the VCP Group board (one of the major
paper maker groups in the country);

Mr. Carlos Aguiar, CEO-Aracruz; Mr. José
Ignácio Ferreira, Governor of the State of
Espírito Santo, and other authorities.
During the inauguration speech, Mr. Fernando Henrique Cardoso stated: “Whatimpresses me more is the imagination,
the ingeniousness, the human capacityof inventing machines and mills of suchmagnitude. Before their construction,
everything has to be planned. And afterwards, persistency is necessary to makethe plan come true. We, in Brazil, need

23
Fig. 1: 3D model.
Fig. 2: Drying and baling line
general view.

2

1

people like those who are implementing
this factory, like the workers and technicians who work here, in this and in manyother factories. We need people who can
put together belief and undertaking capacity, who have working discipline, who
advance within a program.”
During the event, Mr. Lorentzen, President of Aracruz board of directors, recalled that, about thirty years after the
Aracruz inauguration, Brazil is now leading with the world’s largest pulp mill.
“The development provided by companies like Aracruz takes place in the inland
areas, with great environmental and social benefits”, he commented.
According to Mr. Carlos Aguiar, Aracruz
CEO, the investment in this Aracruz expansion was the highest made by theBrazilian industrial sector in recent years.
“The pulp sector is essentially an exporter, a strong generator of foreign exchange to the country, with a positive netbalance of major relevance in the presentdays of our economy”, he stated. With
the inauguration of Fabrica C, Aracruz

will contribute with more than US$ one
billion per year to the Brazilian trade balance, becoming the fifth major generatorof net foreign exchange from exports in
the Brazilian industrial sector.

exports, increasing Aracruz exports to
US$ 1 billion.

The Project

The erection, completed on April 18th,
was the start of the worldwide largest integrated line for the production of eucalyptus pulp, with 2,325 t/day estimated
rated capacity. However, the pulp dewatering machine has already produced
2,444 t/day (production on August 25th,
2002 – 122 days after the machine startup).

The Fábrica C project involved the construction of a new manufacturing unit
(the third one) with a production capacityof 700,000 tons of pulp per year, using
the existent infrastructure. As a result,
Aracruz capacity will be increased to 2
million tons of pulp per year.
The investment in the project was approximately US$ 800 million (US$ 555 million
in the industrial area, US$ 220 million in
the forestal area and US$ 30 million inlogistics and social infrastructure), which,at the time of its realization, represented
the highest investment made in the country by the private industrial sector.
Fábrica C generates of about US$ 350
million additional foreign exchange from

Erection of the drying
and baling facilities

Very motivating right from the start, thisproject was a great achievement and asuperb challenge.
Considering that good planning is essential for any successful action, Voith has
accompanied the whole project step-bystep, right from the start of the work.
With this support to the civil portion of
the work, eventual surprises that could delay the delivery schedule were prevented.

16/03

24

RenatoGuéronDirector ofEngineeringand Projectsof Aracruz
Celulose

Now, after 5 months of operation, we
can confirm that we made the rightchoice.”

16/03

design, its production capacity is twicethat of the two lines (3 and 4) now in operation in the Aracruz Mill B.

Aracruz, the leading eucalyptus pulp producer in the world, already operating with
4 Voith machines, has shown trust in thecompetence of our company by contracting the named consortium. Voith had themain responsibility from the planningphase to start-up.

The choice of the right partners was decisive to enable Voith Paper to reach the
expected result. Voith Paper was responsible for the supply of the presses, thecleaning system, the mechanical erection
and the detail mechanical engineering.
ABB supplied the Flakt dryer; Andritz, theTwin Wire Former – TWF, as well as thecutter, the baling line, the basic engineering, the detail electric engineering andthe electric installation. Moura Schwark
was responsibility for all construction
work.

Despite the great challenge, the companies involved accepted the proposal and,within an exceptional time schedule of 18
months, completed the ambitious Aracruz
Fabrica C Project. Throughout the wholeproject, and in conjunction with a team ofcompetent professionals, the consortium
filled very successfully the order placed
by Aracruz for the supply of the Drying
and Baling Line for its new unit, inaugurated on August 2nd, 2002, in Espírito
Santo.

“The drying machine and the threebaling lines were the installations
supplied by the Voith-Andritz-ABBMoura Schwark Consortium, in thecomplete package modality (EPC), for
our newly inaugurated Fabrica C.
Many excellence aspects were demonstrated to us, starting from the conceptual projects, the after-sales service,
the equipment, very-well developed
logistics with equipment coming from
Brazil, Austria and Germany, very-wellmanaged construction and erection
works, first quality training and commissioning and, finally, a start-up
strictly within schedule and very successful. What also impressed us very
positively were the proactive attitudes
and the clear communication during
the whole project, as well as the efficient ways applied to keep the schedules and to solve problems.

The Consortium – four suppliersin synergy: Voith Paper, Andritz,
ABB, Moura Schwark

The whole technology for the Drying andBaling Machine is innovative. In addition
to its double wire and a more compact
3

At the end of the project, Aracruz invited
all on the project involved personnel to acelebration dinner and, in this ceremony,
paid tribute to the companies for outstanding performance during the execution of the work, by delivering certificatesand placing an advertisement in the media. The Voith-Andritz-Moura SchwarkABB consortium was distinguished withthe “Proactive Partner” category award.

25

4

Fig. 3: Screening system.
Fig. 4: Wet end.
Fig. 5: Baling line.

The Start-up
Thanks to the pre-planning of activities,
commissioning and start-up process proceeded within the usual parameters of an
installation of this magnitude. The synergy among the technicians of the companies involved and Aracruz itself wasnoticeable from the very beginning.

The machine, started-up on August 2nd,
2002, has already exceeded the production parameters, for which it was designed, together with the quality parameters demanded by the customer.
The start-up process of the “Aracruz Fabrica C” project made use of an additional
tool, that surely contributed to accelerate
the machine start-up curve. Aracruz implemented a total process simulator –5 which is as important for the pulp industry as the flight simulator is for the aeronautic industry.
This simulator is an advanced resourcethat allows to check the precision of theautomation and control systems, analyzing early on eventual mistakes in the project engineering. An additional benefit is
the training and qualification of operators
for the system start-up.

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26

A new commissioning
management concept –successfully proven on Hürth PM 1, Germany
Voith Paper’s new commissioning management concept forlarge projects was first implemented with great success on Hürth PM 1.
The new concept is explained here together with its goal set and how
the goal set was reached, the three phases of commissioning management, and results in detail.

Stefan Dette
Paper Machines Graphic
stefan.dette@voith.com

The Hürth PM 1 production line at Rhein

What does commissioning

Papier, a Myllykoski Group member, is aentail?

greenfield plant near Cologne in Germany.
Commissioning activities generally begin
This newsprint line, using 100% recov-

hand in hand with the final erection work.

ered paper furnish, is designed for a
maximum operating speed of 2,000 m/min

To assure the customer a thoroughly

and a trimmed paper width at the reel oftested paper machine ready to go on line

8,160 mm. Maximum annual production

without delay, the subsequent phaseFrank Opletal

is 280,000 tons. The Voith scope of

requires close teamwork between com-

Paper Machines Graphic
frank.opletal@voith.com

supply – stock preparation line, paper

missioning specialists in the areas ofmachine and automation system – is de-process technology, machine control sys-

scribed in a separate reprint.

tems and programming.

Paper Machines

27

Commissioning management:machine controlled by one and the same

goals and how they are reachedcentral processing unit (CPU) – for exam-

but also has a negative effect on morale.

ple, the TQv former and tandem Nip-

A key aspect of the “lean commission-

The primary goal is to ensure a thorough-coFlex press. The tandem NipcoFlex

ing” concept is a well-defined teamly tested paper machine ready to go onpress was therefore commissioned dur-

structure. All responsibilities, both inter-line without delay and without problems.

ing the dayshift, and the former during

nally and toward the customer, are de-In extreme cases, hasty and carelessthe nightshift. This required an additional

fined clearly and unambiguously. The

commissioning can lead to damage andcommissioning team for the nightshift,chiefeven injury during production start-up. To

that included specialists in process tech-charge of site activities and personnel

ensure optimal efficiency and eliminate

nology, machine control systems andthroughout the commissioning phase.

such risks, each Voith commissioning

programming.

Separate commissioning engineers allo-

engineer receives a clear briefing, withcommissioning

engineerisincated to each main section of the paper

adequate task preparation time in Heiden-

Fast commissioning demands strict disci-machine are responsible for coordinatingheim. Furthermore, a detailed checklist ispline among all concerned, and team

activities in that area. This is the only

compiled in advance so that all on-siteplayer commitment is essential. This is

way to ensure efficient and professional

commissioning activities are always un-

the only way to ensure the efficient com-working during hectic phases.

der control down to the last detail.

munication, both internally and with theAfter completing hydraulic system flush-

customer, that is so important for suc-

Successful commissioning also depends

cess.

on profound trust between the customer

ing procedures, Hürth paper machine 1

and the Voith team. Both sides have towas commissioned in 3.5 weeks to stock-

Another important element of Voith’s newcontribute to this, mainly by upholding

on-wire, in full compliance with the tightcommissioning management concept isclear and transparent communications

budget for personnel costs. Although“lean commissioning”. On the just-in-

during commissioning. In the present

commissioning time could have beentime principle, commissioning personnel

case commissioning meetings were heldeven shorter, this would have required an

are not called to site until everything isevery two days between Rhein Papier andincrease in site personnel. Time-critical

ready for them to do their jobs. This

Voith, and an optimization listing for

aspects of the Hürth commissioning pro-eliminates

PM 1 was jointly maintained by the twoject included certain parts of the paper

which not only escalates personnel costs

unnecessary

waitingtime,

partners.

28

The three phases of Voith

Phase 3● All machinery erection work completedcommissioning management

First paper at the reel, 24-hour produc-● All electrical installations completedtion start-up, and initial technological op-● All hydraulic and pneumatic pipe work

Voith’s commissioning management con-timization of the PM.

cept for large projects is divided into thecompleted, blown out and flushed(hydraulics)

A closer look at first-phase activities un-● I/O checks completed

derlines the importance of this planning● Power available to operation station

Phase 1stage. As overall plant supplier, Voith in-(OS), automation station (AS), andPreparation for commissioning prior tosists on thorough project planning priorengineering station (ES)on-site activities.

to on-site activities.

following three phases:● Power available to motor control
centre (MCC); rotational direction

Main tasks:

The main sections – stock preparation● Compilation of a commissioning

line and paper machine – are first inte-schedule defining all intermediate

grated into the commissioning network

targets (time planning)plan. Without fail, the “stock on wire” andchecks completed in test mode
● Availability of steam, water,compressed air and instrument air.

● Definition and fulfilment of man“stock preparation line operational” dead-Particularly important in the second

power requirements (capacitylines must be synchronized. Ideally, thephase are efficient communications and aplanning)

critical time path should include a reserve

solid trust basis between the customerof about 4 days: excessive reserve wastes

and Voith, together with the lean com-human resources due to waiting time.

missioning concept.

After setting these two key milestones,

The third phase of commissioning man-● Customer personnel training

the schedule can be broken down accord-

agement began with a start-up meeting

preparation and support.

ing to start of erection and start of com-

between Rhein Papier and Voith, where a● Internal Voith commissioning kick-off
meeting, followed by at least one
commissioning meeting with thecustomer prior to on-site activities

missioning for the stock preparation line

schedule was jointly established to en-

Phase 2and the paper machine. Before commis-

sure dependable target attainment. The

Thorough dry-testing of all paper ma-

sioning can begin, the following condi-

goal for the first start-up day was stablechine functions.

tions must be fulfilled:

operation of the former and the approach

Paper Machines

29

Highlights of the Hürth PM 1
commissioning from July to
November 2002:
July 4, 2002
First paper at the reel at world record
startup speed of 1,560 m/min.

flow section. On the following day, paper

Summary

was run through the press section.

July 16, 2002
Rhein Papier confirmes Voith contract,that PM 1 produced saleable paperand DIP in continuous operation.

There were three key reasons for the sucOn July 4, 2002 (start-up day 3), a newcess of Hürth PM 1 commissioning:world record for start-up speed was set

1. Ongoing excellence of the Voith One

with first paper at the reel at 1,560 m/min.

Platform Concept for paper machines.

Continuous 24-hour production started

2. Partnership between customer andonly two days later on July 6, 2002. Voith

supplier right through the project andspecialists remained on site day andcommissioning phases. This outstandingnight for two weeks to monitor produc-

teamwork between Rhein Papier/Mylly-tion, carry out optimization, and support

koski and Voith is also reflected in thethe customer’s operating personnel withshort time of only 486 days from placing

intensive on-the-job training. As anotherorder (March 5, 2001) to first paper atimportant commissioning task, they also

the reel (July 4, 2002).

ensured professional site status reporting

3. Professional project management, erec-

and maintained an optimization listing to-tion and commissioning management bygether with the customer.

Voith Paper, both with regard to projectplanning and site activities.

A speed-up trial on PM 1 was scheduled
by Voith commissioning team and theWe pay tribute here to all Rhein PapierRhein Papier production team for Augustand Voith colleagues involved in this6, 2002. On that day the newsprint ma-

commissioning, and to all the respective

chine operating speed was increased

subcontractors.

from 1,560 to 1,912 m/min – an impressive demonstration of this new line’s ca-

The commissioning impressions depictedpacity potential.

above give some idea of how people bothon the side of the customer and the supplies, contributed to this common success.

July 19, 2002
PM 1 gross production for the firsttime exceeded 600 t/24 h paper at thereel (602 t/24 h).
August 3, 2002
PM 1 gross production for the firsttime exceeded 800 t/24 h paper at thereel (809 t/24 h).
August 6, 2002
PM 1 speed-up trial
PM speed increased from 1,560 to
1,912 m/min paper at the reel.
August 2002
Excellent printing results at
Axel Springer Printers, Kettwig.
Axel Springer Publishers confirmed
order for PM 1 paper.
August 2002
PM1 actual average paper production,finished and wrapped: 546 t/day.
Target production according toscheduled start-up curve: 322 t/day.
November 2002
Continuous operation at 1,740 m/min.

30Äänekoski BM 1 rebuild –a particular reference in FinlandM-real Oyj’s Äänekoski board and paper mills are locatedabout three hours by car from Helsinki and only 40 kilometres fromthe parent company of an important competitor of Voith. With anannual output of more than 600,000 tons, M-real is the second
largest producer of folding boxboard in Western Europe. After extensive preparations, Äänekoski decided to establish a new product in the market and to rebuild the existing BM 1. Voith has beenFranz Fischer
Paper Machines
Board and Packaging
franz.fischer@voith.com

16/03

chosen as a reliable partner for the ambitious upgrading of theboard machine and the coating section.

Paper Machines

31

Fig. 1: M-real Oyj, plant Äänekoski.
Fig. 2: M-real and Voith teams signing thecontract.
Fig. 3: Civil works during the rebuild.

Targets of the project2

The project was aimed at producing aboard grade that comes up to the standard of solid bleached board (solid
bleached sulfate, SBS) in terms of brightness and of folding boxboard (FBB) in
terms of stiffness. In other words, thebest properties of SBS and FBB werecombined by using high brightness
BCTMP in the middle layer of the board.
BCTMP is supplied by the M-real Joutseno BCTMP mill.

1

Further strategic goals were to boost theannual production from 115,000 tons to
160,000 tons and to exclusively produce
the new board grades (Carta Solida andCarta Integra) on BM 1. The productionof wall paper base was moved to the
Kyröskoski mill, Finland.

Project phaseÄänekoski board machine 1 was started
in 1966. In the 70s, wallpaper basepassed folding box board as main product. In the 80s, BM 1 was modernized toa flexible swing machine for wallpaperbase and folding boxboard. In 2002,
M-real concentrated wallpaper base production at Kyröskoski mill and Äänekoski
BM 1 was rebuilt to produce exclusively
high-quality board grades for packaging
and graphic end-uses. After the new extensive rebuild, the Äänekoski mill, with
200 employees, will produce 160,000 tons/
year of top-quality virgin fiber board.

Reference visits to other Voith customers
were organized in February and March
2001. In addition, a number of tests were
performed on the pilot paper machine inRavensburg, Germany, in cooperation
with the Äänekoski project team. After a
project development phase of only eightmonths and merely 10 project meetings,
M-real placed the order with Voith on
May 7, 2001, which was the biggest order from Finland up to then.

The partners agreed that the project
development phase had been excellent.
M-real Äänekoski had prepared the project optimally, and Voith was able to start
work immediately after the 1st project 3
meeting in Äänekoski on September 17,
2000. Jointly with the customer, they
worked out a completely new layout for
the BM 1.
The rebuild included an upgrade of thehybrid former, an entirely new press section, a new three-tier dryer section, newheating and ventilating equipment, a new
Yankee dryer, a steam-heated hood, aSpeedFlow, and three new JetFlow F coating units.

16/03

32

Fig. 4: The new NipcoFlex press.
Fig. 5: Coating section.
4

5

Main data of BM 1 after rebuild
Capacity

160,000 t/year

Basis weight

170 - 335 g/m 2

Max. operating speed

660 m/min

Design speed

800 m/min

Trimmed width

3,620 mm

Machine length

140 m

The technology
Wire section
To ensure optimum and reproducible formation, the forming box of the existing
hybrid former was replaced with theproven DuoFormer D forming box.
Press section
Due to the high demands on productstiffness and the limited space conditions, a double-felted NipcoFlex press
was installed in the 2nd press position.
The NipcoFlex press ensures highest dry
contents, thus enhancing not only thequality of the end product, but also theeconomic efficiency of the machine.
Dryer section
The dryer section rebuild was a greatchallenge due to the high capacity requirement and the small space available.
A practicable solution was to install athree-tier dryer section. An optimum layout was worked out jointly with the customer, allowing fast roll and dryer fabricchanges.

16/03

Yankee dryer
A Yankee dryer of 6.7 m diameter, weighing 170 tons, was installed to meet thehigh smoothness requirements. The Yankee dryer hood is steam-heated.
After-dryer section andSpeedFlow
The after-dryer section is of three-tiermodular arrangement. The modular design offers the advantage of five identicaldryer groups, reducing in particular the
maintenance work.
The SpeedFlow size press was installed inorder to meet the high stiffness requirements.

JetFlow F
The printability and the smoothness ofthe end product placed great demands on
the technology used. To satisfy theseproduct requirements, the existing rollapplicators were replaced with JetFlow F
free jet applicators. An essential advantage of the JetFlow F, as compared with aroll applicator, is that the coating color isapplied without being pre-dewatered andneeds not to be re-diluted in the coatingcolor circuit.
In addition, the two existing two-roll calenders were relocated, and the secondary
reel was upgraded.

33

Fig. 6: SpeedFlow.
Fig. 7: Yankee dryer.
Fig. 8: JetFlow F.
Fig. 9: Delivery of the Yankee dryer.
Fig. 10: Reel.
6

7

Exactly on schedule, the Yankee dryer of
6.7 m diameter and a weight of 170 tons
was lifted by a 600 tons mobile cranethrough the roof into the hall on August
3, 2002.
Meanwhile, 56 old dryers and the reused
equipment were refurbished in a workshop, 400 kilometres to the north ofÄänekoski. What a great logistic challenge!
8

The tight schedule of only eight weeks of
shutdown could be met due to perfect organization, and a board web was run as
far as the press-section broke chest on
September 7, 2002.

The rebuild
The last parent roll of board was produced on the old machine on July 18,
2002. Within four days, the complete
BM 1 – except the wire section – was dismantled. Apart from huge construction
work on the machine beam and foundation and the installation of new sole
plates, the first parts for the press section were installed on July 28, 2002.

9

On September 16, 2002, at 00:57 hours,
the first parent roll of saleable board waswound up on the reel.
On the next five days, the three JetFlow F
coating units were put into operation, andthe board grades Carta Integra and Carta
Solida were produced within a few days.

In the meantime, the BM 1 has been further optimized and produces the top
quality expected by M-real at the full satisfaction of their customers.
This rebuild was the biggest order Voithever executed in Finland. Voith proved in
an impressive way that they have boththe technology and the process knowhow to make extensive rebuilds of board
and paper machines a success, thus
helping the customer to be successful inthe market.

10
16/03

34

1

Successful rebuild of two board machinesin Asia by Voith IHI
Voith IHI Paper Technology Co., Ltd. in Tokyo, is a joint
venture between Voith Paper and Ishikawajima-Harima Heavy
Industries/Japan and was established two years ago. Voith IHI
represents the full product line of Voith Paper. Recently, Voith IHI
successfully started up two board machine rebuilds.

Tetsuhiko Nogami
Voith IHI, Tokyo, Japantetsuhiko.nogami@voith.ihi.co.jp

Koa Kogyo Co. Ltd. (Japan)
Koa Kogyo Co., Ltd., has 350 employees
and an annual recycled board production
capacity of approx. 500,000 tons in theirmill near Mount Fuji. Six machines arepresently operating at this location.
Hiromitsu Takaku
Voith IHI, Tokyo, Japanhiromitsu.takaku@voith.ihi.co.jp

16/03

The rebuild
PM 6 originally started up in 1970 andwas rebuilt successfully by Voith IHI in2000 with a double-felted Flexonip shoepress in the third position. Quality improvements due to the shoe press were
impressive and consequently, as a next
step, the customer decided to further improve the product quality by rebuilding
the entire wire section. The machine has

Paper Machines

35

Fig. 1: Koa Kogyo PM 6 – Wire section rebuild,started up on 2003.03.11.
Fig. 2: Koa Kogyo PM 6 – NipcoFlex rebuild
done in 2000.
2

Kenji Ohkubo
Senior Manager
Production
Department, Koa
Kogyo Co. Ltd.

a wire width of 4,320 mm and produces
linerboard with a basis-weight between
160 and 280 g/m 2.
The existing wire section was designed
for three layers, however, it was outdated
from a technological point of view. Therefore, the PM 6 was rebuilt to a mostmodern multi-ply fourdrinier concept(four layers) to be able to produce highquality linerboard more efficiently in the
future. For this reason, three compact
formers were installed for the top, undertop and middle layer. In addition, three
new headboxes were installed at thesame time for best formation.
All layers are produced from nearly 100%
recycled furnish. For the top layer, white
recycled furnish is used.
The main requirements for this rebuild,
like the improvement of sheet formationand strength properties, were completely
fulfilled. At the same time, CD basis
weight profiles could be improved andthe use of chemical additives could be reduced.
Startup
The delivery time for this rebuild was extremely short (8 months) and could only
be met by very detailed scheduling andbest team co-operation.
On February 15, 2003, the machine wasshut down and partly disassembled. Excellent and constructive cooperation between Koa Kogyo and Voith IHI and allother partners involved made it possible
to complete the rebuild shortly ahead ofschedule, and to start production again
on March 11, 2003. The machine produced saleable linerboard from the firstparent roll and presently operates at a
speed of approximately 600 m/min.

“The team of Voith IHI Paper Technology and the staff of Koa Kogyo Co. Ltd.
have done an excellent job. The goalsof the rebuild were achieved and weappreciate in particular the improvement in formation, which enables to
produce linerboard with:● a better surface● improved strength values(by 10 - 20 %)● significant reduction of additives
used (additives were used for higher
paper strength)● a reduction in virgin pulp.
The operation is very easy, and there
are no problems like sheet-breaks in thewire section. We hope this project will
be a long, mutually rewarding businessassociation.”

16/03

36

3

Korea Export Packaging
Ind. Co. Ltd. (Republic of Korea)
Korea Export Packaging (KEP), with 280
employees and an annual capacity of approximately 220,000 tons, is one of theleading board producers in Korea.
KEP was founded 50 years ago with thechallenging target to not only produceboard grades, but to convert their own
products in their own converting units.
KEP has one board mill, the Osan Mill,
which is located near Seoul, and three
converting plants. Only 60 people are
employed in the board mill.

16/03

The rebuild
In Spring 2001, shortly after the establishment of the new Voith IHI joint venture, KEP decided to modify their existing
KM 1 in Osan Mill in order to increase
production and to achieve higher quality.
The KM 1 with a wire width of 4,440 mm
has a three layer wire section and produces mainly testliner in a basis weight
range of 160 to 240 g/m 2 from approx.
85 % recycled furnish.
For the improvement of CD BW profiles,
KEP decided to replace the headbox forthe backlayer with a new MasterJet F/B

headbox. The existing press section consisted of a suction press roll in the 1st
nip and a long nip press in the 2nd nip
and was also rebuilt. KEP decided to relocate the long nip press to the 1st nip position and to install a single felted NipcoFlex shoe press into the second press position.
With all these modifications, dryness
could be increased to approx. 48 % after
the 2nd nip.
The rebuild by Voith IHI led to the expected quality improvement and the desired production increase.

Paper Machines

37

Fig. 3: KEP BM 1 – MasterJet headbox inoperation.
Fig. 4: KEP BM 1 – NipcoFlex rebuild started up
in November 2002.
Fig. 5: KEP BM 1 – Production increase after
rebuild.
4
700

680 tons/day
after rebuild

5

600

500

480 tons/day
before rebuild

400

300

200

100

0
22.11.02
7.12.0214.12.02
18.2.03Date
1.12.0212.12.02
11.1.03

Startup completed
in record time
As Osan BM 1 is the only production machine at KEP, it was essential for the customer to have a short shutdown period
for the rebuild and to avoid any risk ofdelayed startup.
The shutdown was scheduled for one
month. This period was very short, considering the extensive rebuild that included the complete press and other modifications, that were performed by local
Korean subsuppliers.
The machine was stopped mid Octoberand since all people involved exactly fulfilled the schedule, the machine wasstarted up successfully again on November 19, 2002.

Here, too, we appreciate the good partnership between Voith IHI and KEP’s project team, mill management and installation staff to carry out the rebuild asscheduled and to start commercial operations as expected.
It is remarkable that just one month after
start up, the maximum NipcoFlex shoepress load of 1,200 kN was achieved. In
addition, the maximum operating speedof 650 m/min was reached within twomonths after start up and the expected
improvement of the paper quality wasconfirmed. The possibility to reduce thevirgin pulp stock by 20 % is also verysignificant.

S. J. LeeJ. S. Kim

Managing
Directorof Korea Export
Packaging Ind.
Co. Ltd.

Mill Manager
of Korea Export
Packaging Ind.
Co. Ltd.

“BM 1 rebuild project was our firstproject with Voith IHI. All Voith IHI
members have shown great teamwork
capability from the very beginning of
this project. We believe that we owe
this success to their performance.
Through this modification, we haveachieved higher quality and an increasein machine speed, and we enjoy an evenbetter reputation in the Korean market.
We expect Voith IHI to maintain thegood relationship and ask for their support for the further development of ourcompany.”

16/03

38

“Triple Day” in Düren
Presentation of the new three-layer inclined-wire
technology
Under the motto “Triple Day”, Voith Paper welcomed
49 experts from 23 companies, who are familiar with wet-lay
nonwoven production. Guests from 10 countries could convince
themselves of the innovative force and technical competence inthe field of specialty paper machines in Düren.

Dr. Klaus AfflerbachSpecialty paper machinesklaus.afflerbach@voith.com

Triple Day
The event for the presentation of the
newly-developed HydroFormer M3 took
place on April 3, 2003 during a customer
conference in Düren. Mr. Endters, themanaging director, welcomed the guests.
This was followed by various technicalpresentations about inclined-wire technology. On this occasion, the new threelayer HydroFormer M3 was presented
with 3-D animations.
The technical presentations were rounded
off by a guest contribution of a wet-lay
nonwoven specialist. In his presentation,
Gene Reardon from the USA comparedexisting multi-layer technologies in thefield of wet-lay nonwoven production to
the new development by Voith Paper andhighlighted the advantages and flexibilityof the new concept for future customers.

16/03

Between these presentations, the guests
had the opportunity for extensively examining a pre-assembled HydroFormer M3
in the factory shops.
All pneumatic and hydraulic HydroFormer
M3 movements were functioning so that,among other things, the headbox accessibility for maintenance, cleaning andwire change could be demonstrated.
The conference program was rounded off
by the production of a three-layer product on the wet-lay nonwoven pilot unit.
A number of guests took the opportunity
to examine the produced three-layer
product immediately with an expert’s eye.
During an evening banquet, the guests
had the opportunity for an intercultural,personal and specialist exchange of experience.

39

HydroFormer M3
The HydroFormer is a sheet forming unit
on which wet-lay nonwovens and long-fibre papers can be produced. The headbox
operates with stock consistencies of
0.01-0.1%. Due to these low stock consistencies, long-fibre papers with fibre
lengths up to 32 mm can be producedwith homogeneous formation.
Typical HydroFormer products are forexample:● glass fiber mats● tea bag paper● high-porosity plug wrap papers● overlay papers● filter papers.
In the past, Voith Paper produced single
and double-layer HydroFormers. Voith

has a high market share with a total delivery of 54 HydroFormers.
The development of the three-layer HydroFormer M3 was started in Düren two
years ago. Interested customers were invited to get to know the new procedure
after a test phase at the pilot unit.

field of filter papers where products withnew features can be created or in otherfields, where fillers can be embedded between two plies.
The feedback from customers showed
clearly that the relatively small group of
wet-lay nonwoven producers had waitedfor new, innovative solutions.

The response to this was so high that –after successful tests – the first HydroFormer M3 for the production of threelayer specialty papers was ordered with
Voith Paper in April 2002.
The start-up of the new paper machinewith the first HydroFormer M3 is scheduled for August 2003.
The HydroFormer multi-layer technology
allows the production of new wet-lay
nonwoven products for example in the

16/03

40

Copamex –innovative NipcoFlex technology
remains on the advance1

The new crescent former tissue machine with
Vilson Foligati
Voith São Paulo, Brazil
vilson.foligati@voith.com

TissueFlex Technology, ordered at the end of the year 2000
with Voith Paper by Copamex, the second largest paper
producer of Mexico, has successfully been started up.
The machine was built by Voith Paper in Brazil and is dimensioned for a 2,000 m/min maximum design speed, with a wire
width of 3,600 mm, for the production of tissue papers withbasis weights between 13 and 36 g/m2.

Ronaldo Parucker
Voith São Paulo, Brazil
ronaldo.parucker@voith.com

Oscar Campiglia
Voith São Paulo, Brazil
oscar.campiglia@voith.com

16/03

Copamex is one of the leading Mexican
producers of kraft paper for multi-layerbags, bathroom tissue and paper towel aswell as specialty papers. The company is
one of the major producers of bleachedpulp and secondary fibers for recycled
paper for national and international markets.
The development of the TissueFlex Technology is based on the experience that
Voith Paper accumulated as the market
leader of NipcoFlex shoe presses. NipcoFlex presses are on the advance worldwide and are being used successfully inthe production of almost all paper andcardboard grades.
In TissueFlex technology, the tissue web
is dewatered mechanically in the wide nip
between the shoe press roll and the Yankee cylinder.
This innovative idea created a high interest worldwide with the tissue producers.
Continuous improvements and optimizations of the new TissueFlex technology
resulted in today’s production of tissue
of exceptional softness and higher bulk,
important factors for sanitary and facial

Tissue

41

Fig. 1: The Crescentformer Tissue PM.
Fig. 2: Schematic of the Tissue PM.
Fig. 3: The start up team.

2

papers. In addition, the water retention
and absorption of the paper is increased,
decisive quality characteristics for
kitchen towels.
The positive experiences with commercial
installations showed an increase in bulkof 10-20% and 5-8% fiber saving plus
excellent softness. Thus, the expectations
were fulfilled or even exceeded. All
clients share the enthusiasm regarding
the high-quality tissue paper producedwith the TissueFlex.
Voith Paper led a consortium formed byMeri, a joint venture partner of Voith Paper and ABB for the supply of an extensive equipment package for Copamex.
This included, in addition to the complete
tissue machine, a stock preparation line,
a high-efficiency hood for the Yankee
cylinder, and the electric drive as well as
automation and the quality control system.
The stock preparation for virgin fiber witha capacity of 67 bdmt/day bd consists ofthe pulping, cleaning and refining systems. For the approach flow system, thecleaning system and the fan pump were
supplied as well. Fiber recovery from themachines white water circuit was done by

the Meri installed DAF-type clarification
system.
The crescent former guarantees easy operation and allows a higher flexibility forthe production of top quality tissue.
The TissueFlex technology makes the
production of high-quality tissue papers
with increased bulk and softness possible
and enables a reduction of fiber consumption or, alternatively, an increase inproduction capacity. There are now eight
installations worldwide of this innovativetechnology, five of which are in theAmericas.
A 4,572 mm diameter Yankee cylinder,internally grooved, manufactured byVoith Paper Brazil, together with a highefficiency hood by ABB, form a unit thatallows operating the machine at maximum speeds and production capacities.
The end section comprises a complete
reel with reel spool magazine and core
shaft puller plus the devices required tooperate it so as to maintain, as much as
possible, the characteristics of the produced paper during the winding process.
Together with ABB, Voith Paper supplied
the equipment for the tissue machine
3 electric drive and fan pump, as well as all
the DCS control system with automation
for the stock preparation line, other auxiliary systems for the tissue machine and a
QCS quality control system. Voith Fabrics
also provided the machine clothing.
The new PM 1 was put into operation at
the Monterrey mill in July 2002. Approximately three months after the start up,

Mario
GonzalezMill Director
Copamex

José
Peregrina
CopamexResearch andTechnology
Director“We expect that the innovative NipcoFlex technology, developed by Voith
Paper, will allow Copamex to be morecompetitive in the market, both in terms
of price and quality, with its line ofproducts for family hygiene. Privatecompanies need the technological support from groups such as Voith Paper.
The support and commitment by Voith
Paper were very important for us, asthese factors contributed in reducing
the expected down times for the disassembly of the old PM and the erection/
start up of the new machine from thescheduled five months to only threemonths.”the machine has already reached a production of 90 t/day of high quality tissue
papers with basis weights between 13.5
and 15 g/m 2, produced from virgin fiber
and/or secondary fibers. The current
phase shows high dedication and commitment to optimize all machine processes and to adapt the production and speed
levels to those for which the machine
was designed.

16/03

42

1

Lady Regio –Tissue from Copamex wins recognition
in Mexico

The TissueFlex equipped machine, high-performance Voith Fabrics clothing and applications know-how
from Voith Paper are considered fundamental to Copamex
success.

Marc Begin
Voith Fabrics
Raleigh, Georgia, USA
marc.begin@voith.com

16/03

2

Fabrics

43

Fig. 3: Gustavo Elisei (left) of Voith Paper Brazil
and Fernando Lara Muñoz (right) of Voith Fabrics
Mexico provide on-site technical expertise at the
Copamex Monterrey mill.

Fig. 1: Lady Regio Tissue is recognized as apremium brand in Mexico for its bulk, internal
strength and softness.

Fig. 4: Fernando Lara Muñoz (left) leads
Voith Fabrics’ sales and service effort at
Copamex, working closely with Max Molina(right), Copamex machine superintendent.

Fig. 2: Voith’s Omega 2 press fabric provides
optimum sheet dewatering and transfer to the
Yankee Dryer cylinder.
3

4

properties of Lady Regio, he notes, “Thecombination of technology, process
know-how and talent from Voith havesmoothed the way for our initial successand gives us confidence that we will continue to excel in the marketplace.”

Runnability, Fewer Breaks

In less than a year after Copamex introduced Lady Regio bathroom tissue, it has
become recognized as the best quality
brand in Mexico (Revista del Consumidor/Consumer Magazine; January 2003).
Says Juan Manuel Rojas, marketing manager for the Consumer Products Division
at Copamex, “A big effort with market
studies and focus groups helped us develop a tissue product that consumers in
Mexico now choose by a wide margin.”
The market study to determine consumer
needs and desired product attributes coincided with the planning and engineeringof the Voith tissue machine. The productmarket survey indicated consumers wanttissue that is soft and bulky, yet has sufficient internal strength. This helped drive
the decision by Copamex to invest in theVoith TissueFlex shoe press technology.
Rojas is quick to add, “We are producersof consumer products for the Mexican
market, not machine builders and clothing manufacturers. Voith listened to ourneeds, delivered the right machine, finetuned the clothing and continues to help
us optimize long after startup.”

The Making of Lady Regio
Lady Regio is made in the Copamex plantin Monterrey, Mexico, on a Voith crescent
former style machine, which includes TissueFlex shoe press technology. Startingup last July, Copamex was producing 90
tons per day of high-quality tissue after
only three months of operation. In lessthan a year after startup, the tissue makerhas reached 102 tons/day and a 90% efficiency rate.
According to Mario Gonzalez Quiroga,
Copamex mill manager in Monterrey,“Voith has played a central role in our
success through their broad commitment
to helping us achieve desired objectivesof runnability and sheet quality. The
proper machine clothing is essential toproducing the balance of bulk and softness we seek.”
Gonzalez Quiroga says that Lady Regio,
which requires a special balance of softness and bulk, can only be made on theVoith machine. While he acknowledges
that a special blend of virgin fibers andeucalyptus pulps is important to the

Says Max Molina, machine superintendent at the Copamex mill, “Bulk comesfrom the mix of fiber and clothing application. Fernando Lara Muñoz of Voith
Fabrics has led an effort to match forming and press fabrics to our machine.
Now, we have the bulk we desire andlonger wire life, too.”
Molina suggests that when making the
sheet of Lady Regios’ two-ply it is moredifficult to achieve the softness and bulk
targets. As he puts it, “The combinationof Voith’s machine and fabrics makes avery difficult task rather routine.”
The machine clothing is contributing to a
uniform sheet moisture profile, resulting
in fewer breaks, and the high overallmachine speed comes from the ability of
the forming and press fabrics to remove
water with high efficiency, according toMolina.

Voith Tissue Technology
to Fit Market Needs
The TissueFlex concept is a method ofpressing the sheet against the Voith Yankee Dryer with a wide shoe press nip.
Since its market introduction two years
ago, there have been eight commercial

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44

Santiago
Garza
Copamex
Logistics
Manager

Copamex logistics manager, Santiago
Garza, suggests that there is a movement toward better quality in Mexicoand that consumer opinions are finding
their way into Mexico’s products.
In his words, “Consumers have options
that they never had before with products made in Mexico. They set a standard and encouraged pride in workmanship.
Mexico needs to keep growing based on
quality products for the consumer andhave a good atmosphere inside ourmills. When people are treated well in
the plant, they have a sense of ownership.

applications of TissueFlex. The design involves pressing the sheet against thehard Yankee over a longer and, very importantly, lower nip pressure. The lower
nip intensity does not excessively reduce
the sheet’s caliper, thus retaining bulk.
The longer nip and resulting increased
contact time between the TissueFlex
press and the hot Yankee surface provides additional drying, while preserving
the key product objectives.
The Copamex TissueFlex installation was
the third new machine so equipped. The
other applications are press section rebuilds.

Forming the SheetAt Copamex, being more productive,
more active, more involved with fresh
ideas is our approach. And we try tofollow the market niches – this is ourtarget.”By purchasing a complete new machine,
you can receive the benefits of the Voith
headbox, which delivers a uniform jet toa state-of-the-art crescent former configuration.
The sheet is formed on a Voith Enterpriseforming fabric that provides a high-quality, uniform sheet appearance. The sheet
width is precisely determined by theVoith trim beads, which are specially engineered and extruded onto the fabric at
the Voith manufacturing plant.

Pressing and Drying the Sheet
The sheet is then transferred to the TissueFlex nip by Voith Fabrics’ Omega 2press fabric. Prior to entering the TissueFlex nip, the sheet is dewatered through16/03

the Omega 2 fabric matrix and suction
pressure roll. With this equipment andclothing concept, the sheet is lightly
pressed and transferred at the TissueFlex
Press while the caliper is mostly maintained.
The Omega 2 press fabric incorporates apatented Flow Control ® membrane, which
reduces sheet rewet by limiting water migration back to the fabric’s surface upon
exiting the press nip. This is critical in ashoe press because the longer nip dwell
time increases the chances of water returning to the fabric’s surface.
With the sheet dryness maximized at thenip, the machine is allowed to run at ahigher speed and thus improve productivity.
The other vital clothing component is theVoith QualiFlex sleeve, which completely
encloses the TissueFlex roll. It is made of
specially designed reinforced polyurethane and can be supplied with a smooth,
blind drilled or grooved surface. The material composition and manufacture of
the sleeve is both complex and critical tothe machine’s success. The Voith QualiFlex sleeve, together with the Voith press
fabric, has proven to help achieve thegoals of the machine. The resilient sleevemaintains its integrity with each revolution and achieves excellent operationallife.
The tissue sheet is further dried by theVoith Yankee cylinder and the AndritzABB Hoods. The sheet is then reeled,trimmed on the winder, sent to converting to be processed into tissue rolls,
packaged and distributed.

45

Fig. 5: Copamex produces over 100 tons ofhigh quality bathroom tissue every day at its
Monterrey, Mexico, mill.

Successful Startup

Partnership Model

A team from Voith Paper and Voith Fabrics assisted Copamex personnel with thestartup of the new machine. The groupperformed normal fine-tuning once all theequipment was commissioned. Optimization of the system components and machine clothing continued in conjunction
with the Copamex furnish.

Santiago Garza, Copamex logistics manager, sums up the relationship with Voithby saying, “Suppliers are important to us.
We are confident with the Voith brand.
Voith’s machine, clothing, spare partsand service are working. We are trying tobuild this kind of relationship in everything we do.”In short order, the machine meets quality
objectives and produces a well-formed
sheet and firm, bulky rolls of Lady Regio
bathroom tissue.

As Garza sees it, “Copamex and Voith
have formed a partnership in the mannerin which today’s business can be conducted best. Voith can deliver a complete
platform of equipment and clothing towork in unison by understanding theneeds of Copamex.”

From a productivity standpoint, the machine started up quickly and was soon
producing at a speed of 1,600 mpm. An
operating speed of 1,800 mpm wasreached soon after.

One recent example of the partnership
was a successfully completed optimiza-tion project. Copamex and Voith personnel worked together to precisely measureand maximize sheet width delivered to
the TissueFlex press and Yankee cylinder.
Ultimately, redefining the location of trim
beads on the Voith Enterprise forming
fabric and rebuilding the converting
winders with wider embossing rolls
achieved the maximum usable sheet
width and productivity thus reducing trim
waste.

According to Fernando Lara Muñoz ofVoith, “With our Fiber Systems, Voith
Paper and Voith Fabrics groups working
together, we’re able to partner with
Copamex to meet the combined goals of
top tissue quality at a high and efficient
rate of production.”

16/03

46

Norbert Wedler
Finishingnorbert.wedler@voith.com

Leaving nothing to chance –Janus MK 2 calender precommissioning for
Bowater Catawba, South Carolina, USA
Despite the growing complexity of production lines thesedays, faster erection and commissioning are increasingly important
for return on investment – and often decisive for getting the orderin the first place. Voith Paper has tackled this challenge so
successfully that in recent years we have set up a number of world
records for erection and commissioning times. This article aboutPeter Herbrik
Finishingpeter.herbrik@voith.com

16/03

the 8-roll Janus calender for Bowater shows what lies behind suchachievements.

Finishing47

Fig. 1: Janus MK 2 calender during erection andprecommissioning in Krefeld.
Fig. 2: Hydraulic unit supply piping to the Janus
MK 2 from the Nipco roll test rig.

The project can be summarized as fol-2

lows: Bowater installed their PM 3 in1968 as the world’s fastest newsprint
machine at that time, but with the ongoing decline of US newsprint prices in recent years, LWC production became amore worthwhile alternative. Voith received the order for rebuilding the line
accordingly with an EcoCal calender,
Speedsizer, coater, IR afterdrier, Janus
MK 2 calender, Sirius and two drum slitter/winder rebuild.
Effectively, PM 3 thus became almost a

Precommissioning and testing

completely new machine.
Precommissioning was done almost en-

1

The contract specified no more thantirely46 days between shutting down the oldequipment. One of the few exceptions

line and starting up the rebuilt PM 3. To

was the Nipco hydraulics unit. Due to thecomply with such a tight schedule, a lot

size of the oil tank, Nipco roll control andmore is required than the conventionalloading was taken over by an existing hy-

system of site erection unit by unit. Thisdraulics unit used for testing all Voith

demanded complete pre-assembly of the

Nipco rolls. By installing about 400 me-

calender, but that was not enough: totres of hydraulic piping together with nu-

provide the necessary security, complete

merous cables and data buses, this large

precommissioning was also required.

unit has been made ready for precommis-

This article mainly deals with the pre-sioning other complete calenders incommissioning and testing procedure

future. All the structural modifications

rather than pre-assembly.

made will, of course, be retained, so

withoriginal

components

andthat in future precommissioning in the
Pre-assembly

Bowater style can easily be carried out in
Krefeld. Fig. 2 shows the permanentFig. 1 shows the Janus MK 2 calender inhydraulic link now installed for the Nipco

the Voith erection hall – a stately machine

test rig in the final-erection hall.

15 m high x 22 m wide x 15 m long weighing 700 metric tons. About 7,500 man

Since the original valve banks, (Fig. 3)

hours were required for pre-assembly.

required for zone control of the Nipco

16/03

48

Fig. 3: Zone control cubicle for the Nipco rolls.
Fig. 4: Auxiliary roll drive for the calenderclosing tests under additional load.
Fig. 5: One of the regular precommissioning
meetings.
Fig. 6: Calender acceptance and functional
testing.
Fig. 7: Customer training on the Janus MK 2
calender.
3

4

5rolls during precommissioning, were not

All settings were entered in the qualitycommissioning tests also included inter-

available because site piping work wascontrol

ference checks.

already underway in Catawba, the valve

records which had been prepared inbank manufacturer provided mock-ups

advance.

checklists

andacceptanceA special feature of the Bowater calenderfor simulating pipe connections. These

is its control system. Instead of the

mock-ups included all pipe connections

To check and optimize all functions of theSiemens S7 system normally used byin the right positions and sizes, thus en-

Janus MK 2 floating stack – opening,

Voith, Bowater wanted this machine fitted

abling the piping to be laid so precisely

closing and calender load increase – thewith General Electric GE 9030 controls.

that when the original valve banks were

drive motor on roll No. 7 was replaced

For precommissioning, this control sys-

installed later on, everything fitted to-with an auxiliary drive for precommis-

tem was completely installed and con-gether like the proverbial hand in glove.

sioning purposes (Fig. 4).

nected including the original switchgear
cubicles, so that all functional tests could

A main purpose of precommissioning

Precommissioning work was facilitatedbe carried out with the original control

was to carry out functional tests. Theseby first putting the mobile inspection

system software. As a result, all the pro-covered roll stack closing, load increase,platform

madegram adjustments and parameter settings

quick-release stack opening and – lastalmost every part of the calender easily

normally requiring considerable time dur-

but not least – checking and adjusting theaccessible at all times.

ing site commissioning, were alreadyinto

operation.

This

nip line force distribution with pressure-done in the workshops – which wassensitive paper inserts. Furthermore, all

Thanks to complete installation of all

greatly appreciated by the Bowater com-pneumatic units were comprehensively

structural steelwork on tender and drive

missioning engineer:checked and adjusted for perfect opera-sides, as well as the drive framework,tion, such as the roll feed system, doc-cardan shafts, safety hoods and motors –“It’s a great feeling to know in advancetors, guillotines, blower air settings forincluding a timber mock-up of the calen-that the control system is one hundred

web break monitoring, etc., etc.

der columns on site in Catawba – the pre-percent dependable!”

16/03

49

6

7

To familiarize the staff adequately with

program. With a well-balanced mixture of

We followed our motto “Leave nothing to

the GE control system and its program-theory and practice, this held the atten-

chance” systematically and uncompro-

ming interface, precommissioning wastion of all participants from beginning tomisingly. And that certainly paid off:

done with the actual site operating per-end. And when our guests finally said

sonnel. This represents another step in

goodbye, they had no more open ques-● Errors were discovered in good time

optimal know-how transfer right throughtions. Hardly had they arrived back in

and immediately corrected. On site, we

the project, from design to erection to

Catawba when they mailed us the follow-

could, therefore, concentrate on opti-

startup in Catawba.

ing statement:

mization without time-consuming trou-

Daily status discussions held on the spot

“The preassembled Janus calender is● All findings were documented and fed

with all concerned – erection, design,

very impressive. We are all amazed how

straight back to the design and au-

commissioning and quality control spe-thoroughly well thought-out, precommis-

tomation specialists.

cialists – helped to ensure smoothly

sioned and tested this machine is. The● The substantial efforts of this very de-coordinated testing.

entire Voith team also did a fantastic job

tailed work shop precommissioning

bleshooting and delays.

with regard to training and preparation.

significantly shortens site commis-

All in all, about 30 people were involved

We look forward with pleasure and ex-sioning time, which, in the end, hasfor about 4 weeks in the precommission-

citement to the first startup.”

considerable advantages for Voith aswell as the customer.

ing preparations and testing.
During precommissioning in the work

Summary and conclusions

We clearly spent a lot of time and trouble
getting the calender optimally fit for site

shops, a 1-week training course for
Bowater personnel was held in Krefeld.

Never before has the Finishing Divisioncommissioning. And, as shown by the

The instructors were thoroughly preparedcarried out such a comprehensive pre-picturebook startup last March, that paid

and put together a very effective training

commissioning.

off in no uncertain terms.

16/03

50

Roll wrapping systems
for the paper industry –a comparison

Volker Schölzke
Finishingvolker.schoelzke@voith.com

Before transporting finished paper rolls from the mill to
consumers – usually printers – they have to be wrapped to protect
them from damage and climatic effects. This article takes acritical look at wrapping materials and machinery used worldwide
today, and the main differences between them.

One of the main criteria is the kind of

methods for paper rolls: exclusively axial

packaging material used. These days

wrapping, or combined axial and radialplastic wrap materials are used as well as

wrapping.

packaging paper, or a combination ofRolls wrapped exclusively radially withboth.

stretch wrap (Fig. 1) must be protectedby end covers made of boxboard or corrugated carton. These end covers must

Plastic wrap

be quite exactly the same diameter as the1

There are basically two different kind of

paper roll, since they are only held on bywrapping material: shrink wrap

about 100 mm of stretch wrap overlap

andstretch wrap, which is much thinner.

around the edge. While the smooth rollend-covers enable trouble-free vertical

Paper rolls are hardly ever packed instacking, they are prone to fall out during

becausecreaseshandling by forklift truck or due to foil

formed on each end make rolls wrappedslackening, particularly as a result of

like this unsuitable for storage in the ver-long storage periods or light exposure.

tical position. Shrink wrap is only used

This also weakens the wrapped roll as afor special applications, such as for hold-whole. Furthermore, rolls with commer-

ing finished paper rolls on a pallet.

cial boxboard or corrugated carton end

shrink

2

wrap,

the

covers alone are not hermetically sealed

16/03

Stretch wrap is widely used in the paper

against climatic effects. Without PE-coat-industry, with two different wrapping

ed covers, the paper roll can either lose

51

Finishing

Outer headers

Plain paper roll

Wrappedpaper roll3

Fig. 1: Radial wrapping with
Crimping
stretch wrap.
of wrapping
paper
Fig. 2: Radial and axial wrapping
overlapswith stretch wrap.

Innerheaders

Wrapping paper

Fig. 3: Damaged stretch wrap.
Wrapping of
paper roll

Plain paper rollwith inner headers

Fig. 4: Classical roll wrapping
procedure using packaging paper.

4

its original moisture content or absorb

this is with crepe-like packaging paper

pressing at high force against the inner

too much moisture from the outside.

(Clu-Pack/Semi Clu-Pack), using the same

covers including folded overlap. Thisequipment as for stretch wrapping.

method ensures bonding of the inner andRadial wrapping with stretch wrap is of-outer end covers over their entire surface

ten used for internal mill storage purposes, but can also be used as transportarea, and provides a smooth end face for
Packaging paper

easy storage on end (Fig. 5).

storage times. By radial wrapping at a

Packaging paper, the classical wrapping

Packaging paper mainly comprises kraft

drum winder station while simultaneouslymaterial, offers much better protection

or testliner sandwich papers with PE lin-rotating the paper roll axially on athan plastic wrap. At the present time

ing.

turntable (Fig. 2), the roll ends are also

this is still the only suitable way of pack-strength, the roll must be wrapped athermetically sealed with plastic wrap. As

ing paper rolls for long transport dis-least two to four times, depending on thean alternative to the turntable, the plastic

tances and storage times.

quality and basis weight of the packing

packaging for short distances and shortwrap dispenser can travel around the rollTo

ensureadequatewrapping

paper. The wrapping can be further

on a ring for axial wrapping. Additional

Roll wrapping with packaging paper isstrengthened by glueing the outer layers

protection by end covers is also possible,

made up of three elements (Fig. 4). The

together, either with cold or hot glue.

but not often used. Since the rather irreg-

roll ends are first protected from damage

Since the cost of hot glue is steadilyular end faces of rolls wrapped in thisby covers made of board or corrugatedfalling, it is increasingly replacing theway are inconvenient for storage on end,

carton. Then the roll is wound withcold glue formerly used, which is difficult

combined radial and axial wrapping isstrongoverlapping

to handle and not very popular among theonly used for special types of paper.

about 150 mm at each end. This overlap

personnel operating and servicing theis normally folded in automatically towrapping machine.

packaging

paper,

In summary: plastic wraps offer the ad-hold the inner end covers firmly. And

vantages of uncomplicated wrapping ma-

finally a PE-coated outer cover, made ofInstead of glueing the packaging paper

chinery and low-cost materials. The draw-

packaging paper, is generally pressed onlayers together, the PE-lining of the paper

backs are high UV-sensitivity, slackening

top of the inner covers and folded over-can be plastified during wrapping in theof stretch wrap, and vulnerability to dirt.

lap, and then heat-sealed.

same way as with the end covers by heat-

Furthermore,smoothplastic-wrappeding (infra-red radiation), and then therolls are more likely to fall off the forklift

Together with the PE-coated outer end

layers bonded together under pressure.

truck, particularly at low temperatures.

covers, the PE-laminated packing paper

The necessary pressure is already given

And due to stretching, even slight tears

used for radial roll wrapping hermeticallyby the weight of the paper roll as it turns

caused by forklift truck handling canseals the entire roll, as required for theon the support drums during wrapping.

rapidly turn into serious damage (Fig. 3).

majority of paper products.

So the heavier the roll, the stronger theSome of these drawbacks can be avoided

The outer end covers are generally fixed

tection, but very difficult to unpackby wrapping plasticcovered rolls withwithout any additional glue, by heat-seal-

when the roll arrives at the printer. This

paper as well. The simplest way to doing (plastifying) the PE coating andmakes automated or at least semi-auto-

wrap – which is ideal for transport pro-

16/03

52

6

5

mated unpacking machinery indispens-tively protects the roll end from fold im-

possibly problems due to beading forma-able (Fig. 6).

prints and the outer cover can be secure-tion.

ly bonded to the folded overlap.
With spiral wrapping, a PE-laminated

For smaller, lighter rolls, the pressure due
to weight is often inadequate for strong

The larger and heavier the paper roll andstrip of packaging paper e.g. 500 mm

bonding. In such cases there is no alter-

the longer the transport distance, thewide is wound at a sharp angle aroundnative to glueing the outer layers together.

more important it is to use really highthe roll. The desired number of layers is

quality packaging materials.

automatically obtained by correctly selecting the angle or degree of strip over-Due to the small tolerances for end over-lap. Then the roll end edges are addition-lap, either many different packaging

ally wrapped at right angles with a con-

Wrapping quality mainly depends on thepaper widths are required for the widestant overlap of 150 mm (Fig. 7).

materials used and on compliance withrange of roll sizes, or alternative solu-

the close tolerances required for the end

tions must be used.

Wrapping quality

Spiral wrapping is suitable for all rollsizes using a single width of packaging

covers and folded overlap. Packaging
paper made of strong kraftliner can be

For example, radial wrapping can be done

paper strip. This kind of wrap is stronger

glued easily and folded sharply over thewith two or more narrow overlapping

than classical wrapping with packaging

edges. In general the end overlap should

strips. This not only enables an optimal

paper, because the glued spiral layers

not be less than 100 mm and not more

overlap of 150 mm to be set irrespective

closely encircle the roll without any folds

than 150 mm, otherwise too much air willof the roll size, but the overlapping paper

and the vulnerable roll edges are betterbe trapped inside and may lead to burst-

strips can be glued together for greater

protected by additional wrapping. Even

ing. The diameter of the inner and outerwrapping strength. The drawback of thisafter long periods of storage in a damp

end covers must never be larger than thatmethod is higher packaging paper con-atmosphere, the widest spirally wrappedof the paper roll, but can be slightly

sumption compared with the classicalpaper rolls are still in excellent condition

smaller as long as the inner cover effec-

method using only one wide strip, andand perfectly protected optically as well.

16/03

Finishing

53

Fig. 5: Paper roll storage on end.
Fig. 6: Paper roll unpacking device.
Fig. 7: Twister spiral wrapping principle withedge protection.
Fig. 8: Twister roll wrapping machine.
7

8

Spiral wrapping of
paper roll body

Edge protection
on the left side

Edge protection
on the right side

There is no sign of the typical wavinessqualities are liable to marking of the top

per, such as produced by August Koehler(“fish-scale” pattern) otherwise caused

layers, particularly large diameter soft-

AG, to be wrapped with the Twister with-by moisture penetrating the outer layers

wound rolls.

out any marking. Also the large LWC
paper rolls produced at StoraEnso Hagenof paper. For the jumbo rolls longer than
3,000 mm already existing today, and in

During classical wrapping with a wide

Kabel – up to 4,500 mm long and weigh-future for rolls as long as 4,300 mm, spi-

strip of packaging paper, each fold forms

ing nearly 10 tonnes – are perfectly

ral wrapping is certainly the most cost-a pressure point. With overlapping wrap-

packed free of marking thanks to theseeffective and highest quality wrapping

ping using several strips in parallel, thisrubber-covered drums.

method.

beading presses into the top layers of
paper, and with spiral wrapping the edge

Summary and conclusions

Spiral wrapping is not limited to any par-of the spiral winding strip can also markticular roll length, however. Even for thethe top layers. Although such markings

Paper rolls are seldom wrapped withshortest rolls, it is a cost-effective alter-

seldom prevent or hinder further pro-shrink wrap and only sometimes withnative to the classical method and also

cessing of the paper, they are neverthe-stretch wrap. Mainly used for this pur-offers the advantages of stronger wrap-

less undesirable.

pose is packaging paper, which is thehighest quality wrapping and the mostping with better edge protection and uniform fold overlap.

To avoid marking during spiral wrapping,economical for long transport distances

Voith Paper uses rubber-covered supportand storage times, despite higher cost.

A closely fitting wrap is important fordrums in the Twister wrapping machine

preventing the roll from falling out during(Fig. 8). As in slitter-winders, two soft-

Inflexible wrapping systems with numer-

handling by forklift truck and even caus-

covered drums reduce the specific line

ous different winding station widths are

ing accidents. Furthermore, paper is anforce and thus prevent the edge of theincreasingly giving way to flexible mod-extremely sensitive product, highly vul-

wrapping strip from pressing into theern roll wrapping machines, which covernerable to damage. So whatever the kindpaper surface. This system even enables

the entire range of roll sizes with a single

of wrapping, some paper grades andhighly sensitive noncarbon copying pa-

width of packaging paper.

16/03

54

Voith Process Solutions –from source to solution
The economic environment the paper industry operates in
has changed considerably over the last several years. As a result
the industry is obligated to operate their mills in a more cost-effective manner than ever before. Voith Paper recognizes these newchallenges and adapted its Mill Service activities to better help ourcustomers meet these challenges. For this reason a new service
concept called Voith Process Solutions has been introduced to theAndreas Arnhold

market.

Serviceandreas.arnhold@voith.com

Voith
Process
Solutions
From source
to solution

As the industry permanently reviews andbut even more assistance is needed for:evaluates their core activities and makes● Technology, quality and process

cost cutting changes such as reductions● Special service (e.g. automation)in technical staff and reductions in capital● Troubleshooting

spending, papermills now ask for techni-● Process optimization

cal support and operational recommenda-– recognition of bottlenecks andtions in traditional subjects like:

optimization potential.

● Spare parts

16/03● Roll service

At a time when investment money for● Roll covers

new projects is short, mills all over the● Field service

world try to better utilize their existing● Maintenance,

equipment and thus search for machineService

55

Fig. 1: Combined Experience.

Paper offers. Specialist teams have been1established in Appleton, Wisconsin (USA)covering North and South America as

Processexpertisewell as in Ravensburg (Germany) cover-Enhancement
products

ing Europe and Asia.

Maintenanceexpertise

Spare
parts

Diagnostic
expertise

the most effective access to the needed
specialists and tools. Within our organi-

Combined
Know howsation the right specialists can be recruit-

Automation
expertise

Machineexpertise
Field
serviceexpertise

These teams offer the paper industry

Felts andfabrics
Rolls
Roll covers
Roll service

ed from different Voith locations all over
the world – the best for the respective
tasks!
However, before solutions, adjustments,
maintenance assistance, optimizations or
new and more efficient machine components can be put in place, the mill’s targets have to be clearly identified. Before

efficiency increases and for cost effective

Voith Process Solutions has beena recommendation can be given a de-operation. Life cycle management is theput in place by Voith Paper to support

tailed analysis has to be made. Prior todefining issue: improvements and solu-

paper mills and to help them better meet

any analytical activities, a detailed dis-

tions to increase productivity and quality

their needs. This step was taken in ordercussion with the customers’ specialists

over the entire lifetime of a paper ma-

to provide our services in a more concen-

takes place in order to learn what theirchine or mill.

trated and unified form. With this ap-

needs and expectations are. Only after

proach we provide advanced and effective

the targets are clearly defined, proposals

Voith is a full-line supplier offering prod-

solutions that impact the economic bot-are prepared and offered.

ucts and components delivered by experi-

tom line of the mills. These are solutions

enced people with product and process

for achieving improvements in quality,

Analysis and diagnosis come first. In or-

knowledge for all elements and disciplines

quantity and costs, profiles, runnability,

der to start with an optimization programof the papermaking process. Products

mechanical condition and energy.

and to offer recommendations and solutions it is often necessary to carry out aand Services backed by this profound expertise result in service packages which

This new concept was introduced inmachine audit which includes extensive

have a high value to the paper industry

North America last year and has beenmachine condition tests and process(Fig. 1). The goal is to offer assistancesuccessfully established meanwhile intesting. From such audits mills get afrom source to solution.

Europe as well. The market acceptance iscomprehensive collection of data andexcellent, as the mills need what Voith

information

describing

themachine,

16/03

56

2

process, and operation which can beor which concentrate only on selected

Convertingused to plan on investment programs for

sections that are considered to be criti-● Rewinder

future rebuilds or just for quick modifica-cal:● Winder● Packaging planttions. The most important aspects are:
Stock Preparation● Define optimized scope for modernisation/modification● Deinking plant● Stock and water system layout● Drive system (gears, motors)● Identify immediate corrective actions
and maintenance or reconditioning

Paper machineneeds● Stock approach flow system● Establish a base-line for long-term

Electrical system(short circulation)

Automation● Headbox● Field instrumentation● Wire and/or former section● Control systems (e.g. for CD profiles)

for reusing existing components in a

● Press section● DCS system

new configuration● Dryer section● QCS system

investment planning● Reduce technical and economic risk

● Investigate machine behaviour atdifferent speeds.

● Size press● ReelAuxiliary equipment

To cover all these items different investi-

Finishing● Lubrication

gations have to be carried out which● Coating section● Vacuummight include the whole production plant● Calender● Tail threading.

16/03

Service

57

Fig. 2: Resources worldwide.
Figs. 3 and 4: Scope of analyses.
34● General papermaking Process Troubleshooting Tasks● Paper Machine Operational Audit● Complete Machine Surveys● Machine Condition Analyses (mechanical)● Wet End Pulsation Analysis & Stock Flow Survey● Gas Content Measurements● Advanced/Comprehensive Vibration Diagnostics● Press Load Measurements● Moisture Cross Profile Analysis● Miscellaneous Mechanic Inspections● Run-out Measurements● Paper Sample Analysis (Tapio)● Other Process Related Studies● Acoustic Analyses● Thermography Survey (High speed)● Forming Section Drainage Analysis● Strobe Synchronous Video Survey● Vacuum System Analysis● Press Section Water Balance● Press Section Efficiency Survey● Press Fabric Conditioning Study● Roll Cover Conditioning Study● Dryer Section Hood Balance● Dryer Section Steam and Condensate Study● In-Mill Routine Predictive Vibration Monitoring● Training Seminars● Paper Machine Alignment Tasks● Machine Economic Analysis Study

For all areas mentioned above Voithand production. The overall goals are tosibility to do CD moisture profile mea-

Paper Service has created and put inincrease machine efficiency and to detectsurements

place service packages that contain well-bottlenecks and to provide efficient solu-

almost all positions in a running paper-

defined studies. Specialized and experi-

tions.

machine.

mechanical condition tests and inspec-

In this issue of twogether magazine we

In the future you will find articles whichtions over extensive process audits andstart with a series about the extensive ca-

include examples for machine studies

various paper quality tests to concept

pabilities of Voith Process Solutions. We

through the entire papermachine and ad-

studies, capacity studies, simulations andwill continue and give you more detailed

jacent sections, mechanical condition

operational

based on NIR technique on

enced teams cover the scope from purely

Machineinformation and examples about our new

tests, concept and capacity studies, dryer

runnability and safety aspects are includ-

service concept and the background ofsection surveys, reel tests...

ed as well (Figs. 3 and 4).

this valuable product over the next few

assessments.

issues.
The result of these are recommendations
which refer to general operation of the

Today we start with our extensive oppor-

machine as well as to the mechanical sta-tunities for a detailed system analysis ofYour issues are our issues.

tus, the process and the improvement

the stock preparation including deinking

From trouble shooting to processpotential to increase the paper quality

plants. Another article deals with the pos-

optimization!

16/03

58

Technological services
from fiber to paper –a worthwhile investment for the paperindustry?
Dr. Volker Gehr
Fiber Systems
volker.gehr@voith.com

Before answering this question, we need to define theterm “Technological Services”. This article gives an overview of

Voith
Process
Solutions
From source
to solution

Technologicalservicesfrom fiber
to paperhow such services in stock preparation can make paper and board
production significantly more efficient. Maximum efficiency,
whilst still maintaining the required stock and paper quality characteristics, can only be reached by optimum process management(e.g. machine layout and water loop management) and by best
possible long-term operating efficiency of the stock preparation
system (e.g. machine selection and fine tuning, plant and control
engineering).

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Service

Optimization measures for
improving efficiency and/or
quality1

Short-term optimization measureson-site for improving stock
preparation plant performance● Increased stock preparation capacity● Condition diagnosis● Improvement in furnish and hence paper
quality● Problem identification● Reduction in fiber losses and increased
fiber yield● Definition of objectives jointly with thecustomer● Savings in fresh water, energy and additives● Check-out of process and machineparameters● Millwide technological and/or thermal
system balancing● Check-out of control strategy andinstrumentation● Water management (fresh water
consumption, specific effluent volume)● Listing of weak points– Immediate process and machine
optimization– Action catalogue for initiating further
engineering and project work, where
necessary● Reduction in disturbing components anddepositing

Well-proven methods for optimum process
management and functionality are:● System analysis/optimization,
pre-studies and● Customer trials.

(Fig. 3). Selection of the best solution
depends on the specific objectives orproblems and in each case can generally
be defined in initial discussions between
you, our customer and Voith Paper.

System analyses, optimizationand pre-studies

So far we have carried out about 70 extensive system analyses and innumerable
optimizations. The benefits of such measures are illustrated in Figs. 4 and 5.

A wide range of optimization possibilities
are available in paper and board production. These are generated by the constantly increasing demands on furnish
and paper quality on the one hand andnecessary measures for improving efficiency on the other (Fig. 1).
Concrete measures can be derived for therequired improvements and these caneither be implemented in the form of
immediate system optimization (Fig. 2)
or by comprehensive system analyses

Another Voith Paper core competence,apart from system analyses and optimization of existing plants, is project risk
minimization for extensions or new
plants. This needs in-depth analyses andpre-studies (feasibility studies, pre-engineering) and requires a wide range ofmulti-disciplinary expertise and teamwork. Extensive pre-studies over the past
few years have substantially further improved engineering reliability – particularly for extensions – as regards:

59

2

3

System analysis
for optimum plant operation● On-site analysis of your stock preparation
process and documentation of actual plantconditions, including comprehensive data
recording, sampling, laboratory evaluationand technological assessment● Detailed calculations for individual
processes right through to a millwidebalance, together with simulation of
optimum process conditions for:– COD content– stock flow
– water and effluent management– thermal management● Joint establishment of concrete systemsolutions and optimization proposals
together with you, our customer● Specific fresh water consumption● Specific effluent volume● Thermal balance (e.g. heatexchangers)● Sludge and rejects systems● Process and automation concept
In addition, mills are increasingly wanting a comprehensive life-cycle support
for which Voith Paper have developed
their Process Solutions programme – seealso a separate article on this subject inthis issue.

Customer trials
Systems and individual machine trials in
our Research and Technology Center inRavensburg, Germany represent another
tool for improving engineering reliability
and for optimization work. Based on agiven furnish mixture with the necessary

16/03

60

The new laboratory refiner for
quality control and laboratory trials.
4

Benefits of system analyses
and optimization● Detailed report on your actual plantcondition by highly experienced Voith
specialists● Indication of concrete system solutions andoptimization potentials or immediate action
to optimize your plant technology andefficiency● Project risk minimization through in-depth
analyses and pre-studies(feasibility studies, pre-engineering)

6

Advantages of trials in our
Research and Technology Center
under simulated mill conditions● Customized solutions● Risk minimization when implementing
new process concepts● Optimization proposals for existing systems
and machines● Comprehensive documentation of trial
results

Cost reductions through short-term optimization measures
ExamplesMeasures

Cost reduction

Packaging paper plant,
800 t / 24 h

Technological optimization of
the complete stock preparation
systemEuro 1,800,000 per year byincreasing stock preparation
plant capacity and improving
paper machine runnability

Tissue plant, 250 t / 24 h

Technological optimizationof slotted screening

Euro 360,000 per year
by minimizing fiber losses

Newsprint plant,
500 t / 24 h

Technological optimizationof flotation

Euro 62.000 per year
by reducing additives

quality characteristics, such trials enabledefinition of optimum machine layout andsettings for achieving the desired finished stock quality requirements.
Every kind of stock preparation system
can be set up and simulated in our fully
equipped Research and Technology Center. About 35 customer trials per year
have been carried out on average since1978 alone. These figures reflect theenormous amount of stock preparation
know-how we have built up over theyears. An important factor to note is thatthe results can be fully used as basis formill operation since all our laboratory
machines and equipment are in oursmallest industrial scale size.
Another highlight is that we can provide
combined stock preparation and paper
machine trials, since our Board and Packaging Paper Division’s trial paper machine is also located in Ravensburg in thesame building.

16/03

Our Research and Technology Center also
incorporates a very well-equipped laboratory, providing reproducible results byusing standardized data recording on
precisely calibrated measuring instruments (CEPI Comparative Testing Service). More than 80 different test procedures can be carried out according to an
extensive variety of norms such as DIN,
ISO, TAPPI, SCAN, etc. Fig. 6 summarizes the benefits of customer trials in
our Research and Technology Center.

The technological services summarized
here as part of Voith Paper’s Process
Solutions will be described in more detailin subsequent issues of twogether
magazine, using concrete examples.

5Service

61

Analysis of the paper moisture CD profile during
operation at almost every position via adjusted
Near-Infra-Red (NIR) measuring technique
Usually the moisture CD-profile of the paper web is automatically recorded by the QCS (Quality Control System) of the paper
machine together with other important quality information. In caseof irregularities in the moisture CD-profile of the paper web thesestandard measuring points are not sufficient to make a quick andaccurate classification of possible causes. With the help of a mobile
NIR-(NearInfraRed) moisture measuring system, it is possible toThomas Gindele

locate the origins of poor moisture cross profiles with compara-

Servicethomas.gindele@voith.com

tively little effort.

Why are the usually installed
QCS-scanners not sufficient?

● after-dryer section (e.g. condition ofcylinders, etc.).

Often moisture profile problems can beeasily detected, whereas their causes can

Present techniques

only be found with strong efforts. As aand possibilities

first step, it is necessary to quickly locate

Bernd Stibi
Servicebernd.stibi@voith.com

where the moisture variation originates.

The moisture CD-profile is automatically

The QCS can only partly help because

recorded at only one or two points in thedata is recorded after the paper web has

paper machine. Therefore it is necessary

passed the paper machine sections.

to use a method which can be used at

Therefore it is not possible to define ex-any point of the paper machine in order

actly in which section and to what extent

to determine where moisture problems

the preceding sections influence theoccur.

moisture profile.
One method is called the gravimetric
Voith
Process
Solutions
From source
to solution

Technologicalservicesfrom fiber
to paper

Generally the following sections influence

method and is used often after the press

the moisture CD-profile:section. It simply involves weighing the● wire section (e.g. homogeneous fibre

paper samples (dry sample analysis)

distribution and draining)● press section (e.g. conditions in thepress nips, press felts etc.)

Analysis of thepaper moisture
CD profile
during operation
at almost every
position● pre-dryer section (e.g. condition ofwhich have been torn off the paper web.
This method can be used for calculating
the approximate average moisture content of the sheet.

cylinders, etc.)● after online coating/size press(e.g. uneven sizing)

Disadvantages of the gravimetric measuring method are the low resolution in

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62

Fig. 1: Paper web process in the machine.
Fig. 2: Installed measuring system after
the press section.

1 Headbox Wire section

Press section

Pre-dryer section

The measurement system is based on the2

Size press

What is the sensor accuracy?

principle, that water absorbs certain
wavelengths in the infra-red light range

The sensor can measure the relative CD

more than other wavelengths. Therefore,

moisture profile on site, which is thea filtered infra-red beam of a determinedmoisture deviation relative to the mean

wave length range is transmitted onto themoisture. This is sufficient to determine

paper web in the machine. By measuring

the influence of components in the paper

how much of the light is absorbed by wa-

machine e.g. the steam blow box or theter molecules in the paper, the moisturepress felt settings. In order to obtain thecontent of the paper can be calculated.

exact moisture values, the sensor must
be calibrated in the lab. The calibration

In order to use this measurement tech-takes into account the type of papernique, a crossbeam rail is installed in theused, as well as the influences of the pa-

desired paper machine section. A small

per machine. Nearly all grades of paper

sensor crosses the paper web on thiscan be analyzed by this method. After the

cross direction and the rough values ofrail. The sheet support material (e.g. dry-calibration, the sensor can measure thethe measurements. However the biggest

er felt) has a negligible effect on the mea-

CD moisture profile with a relative accu-

disadvantage is the interruption in pro-surement procedure.

racy of up to 0.1 %-moisture. The absolute accuracy is up to 1 %-moisture.

duction for every measurement. This usually prohibits a series of tests or trials.

The installation of the rail is normally

Therefore, this method does not allow

done some days before the actual mea-

The resolution of the moisture CD-profile

optimizing steps to be checked quickly.

surements during a planned machine

is limited only by the size of the mea-

shutdown. So there is no loss of produc-

sured area (Ø 25 mm). For example; withtion. The sensor can be installed anda paper width of 5,000 mm, the maxi-

What does the new techniqueoperated during production. Fig. 2 shows

mum number of measuring points is 200.

offer?

an example of an installed measuring

Whereas a resolution of 50-100 mm is

system at a dryer cylinder.

usually sufficient.

(NearInfraRed) measuring system is de-

The positioning required for an accurate

Advantages of the NIR

scribed, which avoids all of the disadvan-

measurement will be done by an engineer

tages of the gravimetric method.

on site.

In the following paragraphs, the NIR-

To summarise, the NIR-measuring system offers the following advantages:

16/03Service

63

Fig. 3:Paper moisture at the beginningof the pre dryer section.
Paper moisture at the endof the pre dryer section.

After-dryer section

Fig. 4:Paper moisture at the beginningof the pre-dryer section before press felt change.
Paper moisture at the beginningof the pre-dryer section after press felt change.

Reel

54

1.9

52

1.7

50

1.5

48

1.3

46

1.1
0

1000

3000
2000
4000
Distance [mm] DS-FS● measurement does not interfere withproduction

5000

Paper moisture [%-moisture]

4
Paper moisture [%-moisture]3
Failure in felt conditioning

54

52
50

48

46
0

1000

2000
3000
4000
Distance [mm] DS-FS

5000

Example: over-dried CD-profile

consumption) but also the option to

before size-press

speed up in the future.

● it can be used almost anywhere on the
In this case the sheet was over-dried to

NIR-measurements before and after the● the measured values are supplied

avoid problems in the size press thatpress felt change showed that the wet

accurately and can be used for

could arise because of the very irregularpeaks in the CD moisture profile were

optimizations

moisture CD-profile.

caused by felt conditioning (Fig. 4).

paper machine● the measurement point distance issmaller and variable, compared to

The NIR measurement after the press

conventional methods.

section proved that the paper entering
the dryer section had already very dry

Practical experiences

Conclusionedges and some wet peaks across the
profile (Fig. 3).

It can clearly be seen that the NIR measuring system is a valuable tool for theOver the past few years the NIR-measurement system has proven itself during ma-

It was possible to optimize the press topapermaker. The system can quickly iso-chine condition analysis, troubleshooting

prevent dry edges. This allowed the milllate problem areas during operation andand machine startups. The following ex-

to increase the moisture ahead of the size

allows for rapid optimization procedures.

ample shows how this system was usedpress by 1 %. This gave the mill not only

With a small amount of effort, consider-for problem solving.

immediate energy savings (less steam

able time and money can be saved.

16/03

64

The importance of achieving and maintaining
benchmark threading performance
Maximum profitability is the ultimate goal of papermakers worldwide. Papermakers can only be profitable if
machine efficiency is optimized and machine availability is
increased. As a part of the integral machine process, threading has a significant impact on both machine efficiency andmachine availability. These two key areas in turn contributeto the overall profitability.
Elisabeth Rooney
Voith Paper Corporation,
Canada, Tail Threading Group
beth.rooney@voith.com

Only the top 1% of paper machines realize the 97% global benchmark for machine efficiency. The rest, 99% of paper
machines in advanced countries are only
achieving an average efficiency of 8082% in their process. One of the main
reasons for this is inefficient and inconsistent threading performance. Not
reaching the set threading benchmark
consistently has a significant impact on
the overall operation of the paper machine.
A key differentiating factor that sets the
top 1% of paper machines apart fromothers is their consistent threading performance. The top performers can only
maintain these high efficiency levels by
repeatedly achieving their threading
benchmark times. While the average papermaker achieves their threading benchmark less than 50% of the time, these
top producers do so over 95% of thetime.

Four Steps to Achieving
and Maintaining Benchmark
Performance
Any mill can achieve and maintain benchmark threading performance. There are
four key steps in the process:

16/03

Baselining: Determining the machine’s
current threading process, its average
threading times from key points on themachine, and its average number ofbreaks per 24 hours from each point (i.e.
what is current machine performance?).
Benchmarking: Determining what themachine’s threading performance shouldbe, compared to similar machines with
optimized threading processes (i.e. whatshould the machine’s performance be?).
Process Optimization: Implementing
new technology and processes to achieve
the pre-determined benchmark performance level.
Process Sustainability: Implementing
tools or processes to maintain benchmark performance over the long term.

Baselining
The first step is to clearly determine exactly what the current threading process
is. This includes identifying everyone andeverything used to thread the machine,reliability and safety issues, as well as
servicing and maintenance of any equipment, training of operators etc. It is also
important that the mill understand thecollateral impact of its particular threading process on overall machine efficiency, manpower allocation etc.

Paper Machines

65

Fig. 1: Benchmark threading time (indicated inred) compared to the actual average threading
time of a North American paper mill.

● Average number of breaks per
24 hours from various points on themachine (e.g. press section, dryers,
last drying cylinder), and the average
sheet to sheet threading time fromeach key point.
● Any collateral problems resulting fromthe current threading process (lack ofspools at turn-up, excessive ropesystem failures, plugged broke pit etc.)
Only threading time should be included inthese calculations, not downtime due tomechanical or electrical problems, equipment failures etc. In this process, the actual average sheet to sheet threading
time for a particular machine from various start points is being determined byusing the current threading process. Thisis then compared to a benchmark time
specifically calculated for that machine.

Determining Benchmark
Determining the benchmark threading
time is a very important step in optimizing the threading process. Once the current average sheet to sheet threading
time is determined from various points
on the machine, a benchmark time can becalculated. This is accomplished by using
the sheet to sheet threading times frommachines similar to the target machine.
Reference machines must be essentiallythe same age and configuration as thetarget machine, and produce similar

grades at similar speeds. Reference machines should have optimized threading
processes already in place and operational. The sheet to sheet times for thereference machines are averaged, and insome cases a compensation factor isadded to this average time to account fordifferences in basic machine processes.

Process Optimization
Once the threading benchmark is set andthe current threading process evaluated,the mill can determine what the cost ofnon-benchmark performance is. Various
options to optimize current performanceto achieve benchmark performance canbe analyzed, and a plan can be developed
to implement the most appropriate solution.

The Impact of Achieving
Benchmark
Only by consistently achieving benchmark threading times can the global
benchmark for machine efficiency bereached. An ideal threading process canhave a significant positive collateral impact on the overall machine performance,
safety and costs.
Once the target machine’s average number of breaks and average threading
times are determined, and a benchmark
time established for the machine, thenext step is to find out what percentageof time the machine is already threading
at benchmark or better using its current(un-optimized) threading process. One of
the biggest differences with the top per-1

PM “X”
20
16

Minutes

Part of this threading process analysis
should be a thorough review of themachine’s downtime logs. To determine
the correct benchmark, it is important toverify:12840
Jan Feb Mar Apr May Jun Jul Aug

forming machines in the world and therest, is that the top performing machines
perform consistently. In other words
they achieve their threading benchmark
or better performance more than 95% of
the time. Below is an actual customer example from one of Voith Tail ThreadingGroup’s Threading Assessment Reports(TEAMS).
This machine, on average, has one press
section break per 24 hours (@31.4 minutes average), one dryer break per
24 hours, (@28.7 minutes average) and3 end section breaks per 24 hours(@14.9 minutes average). Benchmark
times have been determined for this machine (the red line in Fig. 1). Currently
this machine, even with its un-optimized
processes, already achieves threading
benchmark 13.43% of the time from thepresses, 21.68% of the time from thedryers and 34.57% of the time in the end
section. However, when the impact ofachieving benchmark times versus theircurrent average times is calculated, thepotential time saved is staggering.

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66

Fig. 2: Overview of the components in the
MSP threading process management solution.

WebVision

Table: Total annual savings (in minutes)
realized from a consistent threading performance.

Accumulative Annual Threading Savings
Current

Benchmark

Savings(min)

Press to Reel

10,833(1/24h@31.4 min)4,140
(1/24h@12.0 min)6,693

Dryer to Reel

9,902
(1/24h@28.7 min)3,450
(1/24h@10.0 min)

6,452

End Section

15,421(3/24h@14.9 min)

5,175
(3/24h@5.0 min)10,246

Total Savings

At the end of a 345 day year, the total
potential machine availability gain is
23,391 minutes translating into 391 hours,
or 16 days!

23,391

VControla machine is obvious and the payback isimmediate.

Sustainability
This is 16 days that this machine operated and did not make any product. This
loss is avoidable. It is the result of 5 minutes here, 15 minutes there, 10 minutes
over there i.e. an inconsistent, unreliable
process.
In order to calculate a dollar cost of thisloss, we recommend using operating
costs, not lost revenue. This example andpayback calculation does not include savings realized from collateral impact suchas plugged broke pit, lack of spools atturn-up etc. In the current market, even if
a machine is in curtailment for a part of
the year, if it can run more efficiently
when it is operating, the operating costs
saved go directly to the bottom line.
For machines like the one in our example,
operating costs range from $ 5,000$10,000 per hour. The justification for
optimizing the threading process on such

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It is not enough to simply improve theoverall threading performance. Once thebenchmark threading performance isachieved, it has to be sustained. For themill to gain the greatest system lifecycle
ROI, the threading process must continue
to perform at maximum performancelevels over the long term. The biggest
challenge today is not to simply achieve
superior threading performance and safe
operation at the lowest cost, but to maintain the efficiency gains and the ROI overthe long term. It is critical to integrate
service and maintenance (i.e. process
sustainability) into the overall threading
process.
Automated threading technology that dramatically and consistently reduces
threading time allows more efficient manpower allocation and threading processmonitoring. A more efficient threading

process is the basis for any long term solution. This requires more than just goodequipment and an appropriate applicationof the equipment in the machine. It requires process control. Sustained threading performance requires a control system designed to ensure that all parts ofthe process perform consistently, a system that instantly reports when any component or operation falls below the predetermined required optimum performance levels.
To accomplish this, Voith developed andpatented a threading process and management solution, MSP (Maximum Sustainable Performance). MSP manages theentire threading process and ensures
Maximum Sustainable Performance overthe long term. The MSP management solution uses four key components:● Visual Digital Recording Technology(WebVision)● Equipment Controls Technology(VControl)● Equipment Management and Tracking
Data Base (VTrac)● Communication Manager (VMonitor).

Paper Machines

67

Fig. 3: The importance of sustained
performance in the threading process.
MSP Life Cycle Management Tool
Maximizing Customer Gain
 Investment costs
 Investment Gain MSP Costs
 MSP Gain

VMonitor

VTracchine parameters that affect threading sothat problems are quickly identified andcorrected.

ROI

Maintenance andSparesManagement

Once the threading process has been accurately defined, and then optimized, theMSP threading process management solution can maintain this optimum performance. It ensures fast, accurate threading system assessment and diagnostics,
provides remote troubleshooting, eliminates operator variability, reduces downtime and lowers operating costs. In
short, MSP gives the mill complete control of their threading process.
Key benefits of Maximum
Sustainable Performance
Fully automated threading
The MSP system provides fully automaticthreading operation which eliminatesvariability in the threading process, andremoves operators from the machine during threading for improved safety.
MSP provides fast, accurate
and effective troubleshooting
and monitoring
The system keeps track of all the components of the threading system and logs
threading performance. If there is a problem with any parameter that affects
threading such as rope tension, plugged
air jet, moisture content of the tail etc.,
VMonitor sends an appropriate error
message to the operator. VMonitor diagnoses equipment components and ma-

MSP provides remote trouble
shooting 24/7
VTrac maintains a visual and a data log of
performance of specified system components allowing for effective remote troubleshooting. Mills with MSP are able toreceive accurate remote troubleshooting
assistance from threading experts 24/7
because technicians can connect to thesystem through a communications link
and view exactly what is happening withthe system currently and historically.
Technicians can either make the appropriate corrections remotely or assist themill to make them.
MSP provides maintenance andservice management
MSP provides ongoing performance logging, and complete system diagnostics toensure threading performance is always
sustained at maximum efficiency.
VTrack logs all data on the system, monitors equipment performance and sends
appropriate messages to operators when
adjustments are required. VTrack also
sends messages to the operators when
maintenance or service is required, whenspares should be ordered to be on site
for the next shut etc.
VTrack assists mills in making
appropriate ROI based sustainability decisions
Maintaining an ongoing ROI, VTrack assists mills in making appropriate sustainability decision.

Gain

3

Upgrade100%
95%
MSP Gain
Investment Costs

Service0Standard Investment Gain

1

2

3

4

5

Years

Summary
Reaching and sustaining benchmark
threading performance is a key factor inachieving maximum machine availability
and efficiency. Only papermakers who
consistently achieve their threading
benchmark, can achieve global benchmark machine efficiencies.
However, once the threading process has
been optimized to achieve benchmark
performance consistently, steps must be
implemented to ensure this performanceis sustained. Without sustained benchmark performance, machine efficiency
will rapidly decline. The MSP system wasdeveloped to help with the maintenanceof the threading system and ensure consistent benchmark performance. The first
MSP system is installed and operational
at a mill in Western Canada. The 2nd
system is currently being installed in amill in the US.
The MSP solution is a proven diagnostic
and control tool that allows a mill to easily and positively manage the threading
process for sustained optimum results
and increased overall machine efficiency.

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O

RP

S

68

O R AT E N E

WKrieger activities in Latin America
The successful track record of Krieger products in
the Latin American paper industry goes back more than adecade. They comprise various drying systems with gas-fired
infra-red heaters and air hoods for paper machines and coating lines, as well as the Krieger contactless web guiding
system.
1

2

Hans-Peter
Schöpping
Krieger GmbH & Co. KG
p.schoepping@krieger-mg.de

Krieger’s Latin American activities started

Apart from Brazil, Krieger’s biggest mar-tions. Efficient maintenance services andin the early nineties, and until 1998 thisket region, the company’s infra-red driers

fast spare parts procurement ensure theirmarket region was served by Krieger Cor-are now in service on production lines

high availability and cost-effectiveness.

poration, Enfield/CT, USA.

belonging to Smurfit/Mexico, Kimberly
Clark/Mexico, Smurfit/Venezuela, Propal/

Krieger can meet all kinds of specialized

In 1989 the first Krieger drying system,

Columbia, CMPC/Maule in Chile, andcustomer needs with its range of drying

with gas-fired infra-red heater, went into

Fanapel in Uruguay.

systems. For example, Krieger metal IR
radiation driers are ideal for firing withservice at Jefferson Smurfit in Venezuela.
In the next few years Suzano, São Paulo,

Krieger IR driers now command more

the liquid gas (LPG) fuel widely used in

Brazil equipped their paper machines inthan 90 % of the Latin American market,

the region.

the Suzano and Rio Verde mills with

due above all to their outstanding reliabil-

Krieger infra-red driers and a Krieger CB-

ity. Customers also benefit from local

The Brazilian market is always open to in-Turn contactless web deflector system.

service expertise with highly qualified

novative developments, and it was heretechnicians, supported directly from thewhere the first Krieger CB-Turn contact-

Afterwards, other leading Brazilian paper

Mönchengladbach headquarters in Ger-

less web turning systems was commis-

and board producers such as Votorantim

many.

sioned at the Suzano Rio Verde mill. This
new concept not only improves web sta-

Celulose e Papel, Ripasa, Klabin and Ibema also decided for Krieger infra-red dry-Thanks to close customer relations,ing systems, air hoods and web guiding

Kriegersystems.

rapidly and dependably to different condi-

16/03

dryingsystemsareadaptedbility, but also reduces air throughput.

Corporate News

69

Fig. 4: Krieger CB-Turn contactless
web turning, usually installed after
double and single sided coater lines.
Fig. 5: One Platform Design with
Krieger integrated dryer, installed at
Ibema Brazil in 2003.

Fig. 1: Installation at the Suzano Rio Verde mill,Brazil.
Fig. 2: Krieger infra-red drier (K6500 metalradiator, dual line installation between the blower
and suction ducting of the air circulation system)in service at Ibema Brazil.

Fig. 6: The Krieger headquartersin Mönchengladbach, Germany,
currently employing 96 people inproduction, service, design, development, marketing, sales andmanagement.

Fig. 3: Combined infra-red drier, similar to theinstallation at Ripasa Brazil.
3

Circulation-air
Hotair dryer

Combustion-air Fresh-/exhaust-air
Hotair dryer
Heat exchanger

4

5

Burning chamber
Krieger
CB-dryer

Circulation-air Exhaust-air fan
Infra-air dryer Infra-air & hotair

Combustion-air Infra-air dryer

6

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70

P

A

PE

R CU

R
LT U

E

1

It can’t be cardboard – or can it?
The Kreuzberg district of Berlin has always been the homeof eccentric characters and original ideas. Despite the building boom
and all the changes Berlin has undergone since reunification, withimpressive modern buildings made of glass and concrete, this districtin the heart of the German capital has managed to keep some of theold Berlin charm alive. Julia Büttelmann, born in 1961 and masterbookbinder, has her studio here. After various stays abroad and several involvements in exhibitions and awards, including the first prizein the Berlin regional competition for handicraft design, she has established herself here. And that's not by chance! This artist’s unusual
work displays an evident affinity with the environment surrounding her
domicile, part of the contrast between futurism and nostalgia.

16/03

Paper Culture

71

2

3

Fig. 1: Shoe object ‘Evita’, 1996,
shoe size 37, high-heeled sandals;
pasteboard, printed paper, card andcardboard.

Fig. 2: ‘Collective Cups’, 1998,
object with two cups and tray;
dyed paper, card and cardboard.

Fig. 3: ‘Heart-shaped Commode’,
1997, height: 50 cm, with two
drawers and tray; varnished paperand cardboard.

Her small shop in Riemannstrasse is“Everybody knows them, the things

are the sources of Julia Büttelmann’s cre-called “Papp-Show” (“Cardboard Show”)

of everyday life: a vase, a shoe, a chest of

ative artwork.

and is a sales and exhibition room, de-drawers or something else, and each ofsign studio and workshop all rolled into

us has of picture of these objects in our

The cup made of cardboard turns a utility

one. From a pink-coloured staircase, visi-mind’s eye with very specific materials.

item into an illustrative object, whichtors enter the basement, that area typical

Julia Büttelmann practises the art of re-opens up entirely new sight and touchof almost all the buildings in the area

defining the contents as we have so far

perspectives. These works are real but

originating from the Wilhelminian era.

envisaged them. The artist cultivates thesurreal, and what additionally charac-

Generations of craftsmen, milliners andapparently banal material of cardboard byterises them is the good humour they

shoemakers, washerwomen and menders

removing its conventionality. She amazesradiate,” according to a fitting iconology

worked in these rooms, developing their

us with the unexpected in a most artistic

by Ruth Mahr about the paper and card

creativity, their philosophy of life andmanner. On the one hand, she continues

artist and the message her work conveys.

their survival strategies here. It seems as

the tradition of bookbinding with perfect

And the newspaper “Berliner Zeitung”

if Julia Büttelmann’s work possesses aworkmanship; on the other hand, shewrites: “The name ‘Papp-Show’ says itlittle of the wit and the irony with whichgoes beyond this and combines ideas andall, because all of her objects designed inpeople here knew how to face up to thematerials to arrive at scurrile but aesthet-

cardboard are small productions ‘of ahardships of everyday life.

ic forms of expression. Fantasy and irony

somewhat different taste’. At a first

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5

Fig. 4: ‘Red Star’ stool, 1997,
height: 90 cm, width: 90 cm;
paper, cardboard and leather.

glance, you admire the colourful and artistically created cardboard bags that arecrocheted with shining chain-stitch bands.
But if you take a closer look, you noticethe coloured copy of a vulgar, spotty
slice of ham sausage decorates the frontof the small, delicate bag.”
And what does the artist herself
have to say about her work? – “My fascination for paper was aroused when, as achild, I received a blow-up Chinese ballmade of paper. It had all the characteristics of paper that still fill me with enthusiasm today. It was light but none the

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Fig. 5: ‘Bedside Table’, 1997,
height: 60 cm, width: 50 cm;
varnished paper and cardboard.
Fig. 6: ‘Shoulder Bag’, 1997,
height: 28 cm, width: 30 cm;
printed paper, card and leather.
Fig. 7: ‘Wristwatches’, 1997;
varnished paper and card.

less durable – and it gave me a lot of

day are durable enough to be worn for

creator does not wish her work to bepleasure. My ideas developed slowly. As

any length of time? The amusing way inknown only from exhibitions and muse-a master bookbinder, I naturally makewhich she distances objects from theirums but to be mainly in the hands ofboxes and slipcases. These developed

natural setting allows her to look at

people who share her love of ‘a some-

into small chests of drawers and bedsidethings in different ways, using new

what different taste’.

tables. Bags and jewellery followed later.

shapes and colours and giving them a

I had the opportunity of making shoes forbeauty and transience in keeping with the

A look at the ‘Papp-Show’ in Kreuz-a year, thanks to a grant that meant I wasconstant changes of contemporary taste.

berg is most certainly worthwhile for vis-

able to discover new paper processing

Julia Büttelmann’s works are durable. Her

itors to Berlin who have a penchant fortechniques for myself.”trained craftsmanship and her drive de-paper design – even if only to rediscover

mand that of her work. Her extravagant

how infinitely diverse, exciting and posi-

Whether her shoe creations could

boxes and small cabinets can be used totive working with paper and card can be.

actually be worn? The answer is no. They

store all kinds of utensils, and her watch-

are simply decorative objects. But which

es and bracelets can be worn as well.

extravagant, truly fashionable shoes to-

They are affordable, too, because their

Manfred Schindler

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