16

1

Paper Machinery Divisions:

Bowater Halla one of the most efficient
newsprint paper mills world-wide

The author:
Dr. techn. Herbert Ortner,
Paper Machinery Division
Graphic

In the third quarter of 1998, less than
two years after Bowater Halla Paper Co.,
Ltd. South Korea, started production of
its Voith Sulzer newsprint paper machine, PM 1 achieved an absolute efficiency of approximately 89 % (according
to CPPA) and, thus, Bowater Halla Paper
Co., Ltd., became one of the most effective paper mills world-wide. With a sustained operating speed of 1500 m/mm,
already reached in September 1998, thispaper machine is the fastest in operation
throughout Asia. These achievements
should be a good reason to reflect on the“Halla PM 1-project” by providing a shortsummary of the events.
The Bowater Halla Paper Co., Ltd. located within the Daebul Industrial Complex,
Yongam District, South Cholla Province,
not far away from the fishery-harbour

town of Mokpo in the south-eastern partof South Korea, is built on an area ofmore than 400.000 m 2 in close proximity
to the ocean. For further plant expansion,
Bowater Halla Paper owns sufficient additional free land area, directly adjacentto the existing paper mill. In the early
1990ies, the government of South Korea
began to build up the Daebul Industrial
Complex, especially, in order to encourage the investment in industrial venturesin this former agricultural and fisheryregion.
The contract signing on June 14, 1994,
was the fulfilment of a vision of the thenpresident of Hyundai International Inc.,
Dr. Chung In Yung, conceived in the mid1960ies, to build a newsprint paper millin Korea, utilizing 100 % deinked wastepaper as raw material. It was also thePaper Machines

17

Fig. 1: Bowater Halla Co., Ltd. South Korea.
Fig. 2: 4-stage cleaner plant, type KSE with lightweight particles seperation.
Fig. 3: Peroxide Disperger bleaching stage.
Fig. 4: One of the multiinjector flotation
machines, type E.
234

result of Dr. Chung In Yung’s long lasting friendship to the Voith Group ofCompanies, and especially, to the thenvice president of the Voith Stock Preparation Division, Dr. Herbert Ortner. Moreover, Dr. Chung In Yung’s (now Honorary Chairman of the Halla BusinessGroup) conviction that buying from Voith
not only meant obtaining the best technology, but also first class consultancy
and services, was decisive for the awardof this so important order to Voith.
The contract came into force on September 26, 1994 and construction work
started in February 1995. Due to the adverse soil conditions at mill site several
hundred concrete foundation piles, eachmore than 20 m long, had to be driven
into the ground. This extensive additionalfoundation work lead to a three-months’
delay in commencement of paper machine erection. When, at last, on December 10, 1995, everything was ready forthe beginning of erection, deep winter,with icy temperatures and snowstorms,
had set in – causing severe handicaps.
Especially, the laying of sole plates and18

Paper Machines

Technical data of the Halla paper machine No.1:
Untrimmed paper width: 7940 mm
Paper quality: newsprint paper 40 - 48.8 g/m 2
Production capacity: 837 t/24h at 48.8 g/m 2
Construction speed: 1700 m/min
Operating speed: 1500 (1600) m/min
Raw material: up to 100 % deinked wastepaper.

many other activities were massively impaired. But inspite of all these difficulties
and certain cultural misunderstandings
with the Korean contractors – Voith
Sulzer was only responsible for thesupervision of erection, commissioning
and start-up assistance – erection work
was accomplished within a record timeof a little more than eight months andcompleted on August 30, 1996. Start-up(stock on wire) was on September 19,
1996 at a paper machine speed of 1150
m/min. Continuous operation (shift operation), that is to say commencement ofcommercial production, started fourweeks later, on October 19, 1996.
Because of the fact that beside the Voith
Sulzer Paper Technology supplies, theKorean partners, Halla Engineering &Heavy Industries and LG-Machinery,
were involved in the delivery of equipment and components, the project
management as well as erection
management had to deal withvarious, and sometimes
very difficult coordinat-

19

ing problems. These problems, however,were overcome by the sheer determination of all partners involved, byVoith Sulzer Paper Technology, by HallaEngineering & Heavy Industries Ltd. andby Halla Pulp & Paper Co., Ltd., whoworked all with great responsibility andfarsightedness; this also holds true forthe design coordination, the plant engineering, the engineering of the control &instrumentation for the entire plant, andfor the process control system.
For the project “Halla PM1” Voith Sulzer
Paper Technology supplied:
I The complete flotation-deinking plant,
including two Ahlström Fibreflow
drum pulpers, Kvaerner-Eureka disk
filters, Peroxide disperger bleaching
and a Hydrosulfite post-bleachingstage for an accept capacity of
840 BDMT/24 h;
I The complete reject treatment andcircuit water clarification withmachinery and know-how by MeriEntsorgungstechnik;
I The stockpreparation for purchased
thermo-mechanical pulp (TMP) for an
accept capacity of 125 BDMT/24 h;
I The approach flow system with
Deculator, Kvaerner-Eureka disc filter
for fibre recovery, broke treatment andbroke screening;
I The complete paper machine with
GapJet headbox with Profilmatic,
DuoFormer CFD, DuoCentri II press
section with fourth press, CombiDuoRun dryer section (60 % singletier, 40 % double tier), Speedsizer
with GAW starch preparation, Softcalender (2 x 1 nip) with Nipco ® rolls,
Reel with automatic Jumbo rollchange;20

Fig. 5: Softkalender.
Fig. 6: Duo Reels II.
Fig. 7: Roll wrapping system.
5

6

I Finishing with two DuoReels II and thecomplete roll wrapping and rolltransportation system;
I The engineering and the hardware of
the control and instrumentation including the process control system, andI in cooperation with Halla Engineering& Heavy Industries Ltd., the plantengineering.
Siemens supplied the electrical drives ofthe paper machine and the two DuoRollers II. Moreover, a great number ofEuropean and Korean firms participatedin the realisation of that ambitious
project.
With a freshwater consumption of approx. 12,5 m 3 per ton of produced paper,
resulting in an effluent of about 11,0 m 3 ,this newsprint paper mill really sets new
standards.

7

Due to the economic crisis in Korea, theHalla Business Group, like so many otherlarge Korean corporations, experienced
financial difficulties by the end of 1997.
After extensive negotiations the newsprint paper mill was separated from the
HALLA Business Group and taken overby the US-American Bowater Inc., Calhoun, Tennessee, in July 1998. Bowater
Inc. is proud of this acquisition because
now Bowater Halla Paper Co., Ltd. is oneof the most modern newsprint paper
mills within the Bowater corporation.
In order to further improve efficiency,
productivity and product quality, andalso for the best utilisation of the plantpotential, an even closer partnership andintensification of cooperation with Voith
Sulzer Paper Technology is planned.

21Paper Machinery Divisions:

Speedcoater for Chinese market leadership
The Shandong Huatai Group, Dongying,on the second alternative, using Voith

Shandong province, is one of China’s

Sulzer Paper Technology. And we are

hundred largest paper producers. By

convinced that other Chinese paper mills

adding a Speedcoater and an Ecosoft

will soon be following this example. For acalender to its production facilities, thevery good reason: system components

group has now become national leader insuch as the Speedcoater and Ecosoft

the online production of LWC papers.

calender are outstandingly suitable forsuccessful

rebuilds

andconversions.

A good many Chinese paper mills are

Thanks to substantially greater value

currently faced with a fundamental deci-

added, combined with production costsion. Should they invest in the new, wider

reductions, such investments pay off very

paper machinery essential these days forquickly.

cost-effective newsprint production? Or
is it better to convert existing machinery,

The upgraded machine in Dongying, one

usually smaller, for producing wood-freeof 23 operated by this company, operates

LWC grades of higher quality?

at 550 m/min with a wire width of3250 mm. After conversion, LWC papers

After carefully weighing up the pros andwith basis weights of 40 to 80 g/m 2 willcons, the Shandong Huatai Group decided

be produced on this machine.

22

Tandem NipcoFlex press with four felts

ModuleJet headbox with 2D control

Optimally uniform paper surface quality
Optimal equal-sidedness
Optimal runnability thanks to practically closed web run
Extremely high dry content
Designed for the highest operating speeds

Optimal basis weight control
Shortest possible correction time

DuoFormer TQ
Excellent paper uniformity with regard toformation, basis weight profile,ash profiles and sheet structure

Paper Machinery Divisions:

One of the fastest SC paper machines –large order placed by Lang Papier GmbH,
Ettringen, Germany
After joining Myllikoski of Finland, theschinen GmbH received an order in

Bavarian paper manufacturer Gebrüder

May 1998 for the biggest investment

Lang GmbH, Ettringen, realigned produc-

ever made by Lang Paper GmbH. Thistion to high grade uncoated printing

comprised a complete new production

papers with high recovered fibre content.

line for newsprint and SC papers, with an

As always, the goal here was optimal

annualquality at lowest possible production

tonnes.

outputcapacityof

280,000

costs and furnish prices (up to 85%
The author:
Thomas Schaible,
Paper Machinery Division
Graphic

DIP). In the meantime, this company has

When the new COMPACT PM 5 starts up,

become a pioneer in online calendered

the existing PM 3 will be taken out of

paper development and production.

service. The Ettringen mill will then havea total capacity of about 420,000 tonnes

Based on years of fruitful teamwork in

p.a., comprising about 160,000 t.p.a. ofplant modernization and product quality

newsprint and 260,000 t.p.a. of magazineenhancement, Voith Sulzer Papierma-

paper.

Paper Machines

Air handling system

23

Online Janus calender

Dryer hood with duostabilizer system forexcellent runnability andminimal energy consumption

For machine-finished calendering of SC grades
to achieve optimal smoothness and gloss values

Rewind station with Sirius concept

TopDuoRun dryer section

Maximum possible reel diameter
thanks to linear-load-controlled reelingfor optimal roll structure and uniformity

Reduced and more uniform shrinkage
to improve paper quality
Permanent support of paper web on dryer wirefor optimal runnability and control

On June 8, 1998 the first excavator got

The new COMPACT PM 5 in Ettringen

down to the job in Ettringen. Installation

represents the online machine concept ofMain data of the newof the new machinery should commence

the future for SC grades. It comprises an

COMPACT PM 5

in February 1999. And plant commission-

optimally

ing is scheduled for the third quarter

technical synthesis of well-proven sys-

Wire width 8900 mm

1999. A tight schedule indeed, but thetem components, logical developments

Working width with cutoff 8150 mm

machinery design demanded at least as

andMax. winding diameter 3700 mm

much concentrated effort.

overall result is a fully integrated design

Max. rated speed 2290 m/min

for first class end product quality.

Max. operating speed 2000 m/min

efficientfuture-oriented

andcost-effective

innovations.

The

Production capacity 280,000 t.p.a.

Comprehensive optimization studies first
had to be carried out – one of the main

Apart from this new PM 5, the project as

Products: 40-48.8 g/m 2 newsprint,

reasons why Voith Sulzer Paper Technol-a whole also includes investments for

45-60 g/m 2 SC grades

ogy were selected as a competent andcapacity increases and modernization ofCommissioning date: third quarter

dependable partner for this challenging

energy supplies as well as water and

1999

task.

effluent systems.

24Paper Machinery Divisions:In-line SC papers – Dolbeau PM 5
In 1994, the Canadian pulp and paper
giant Domtar split off their groundwood
paper division as an independent company. The new company was named
Alliance Forest Products, and its management moved quickly to upgrade fromnewsprint to higher value products.

The author:
Gareth Jones,
Voith Sulzer Paper Technology
North America, Appleton

The first project carried out was the rebuild of No. 5 paper machine at Dolbeau
mill in the Lac St. Jean area north ofQuebec City. After careful project studies
and pilot trials, Alliance entrusted therebuild to Voith Sulzer Paper Technology.
In the end, the only parts of the existingmachine to remain were the drying cylinders.
The machine configuration chosen was
as follows:
I GapJet headbox with ModuleJet for
dilution control
I DuoFormer CFD
I DuoCentri II press
I Combi Duorun drying section
I Two soft calenders
I Pope reel

The concept was developed in close
teamwork between Alliance, the consulting engineers and Voith Sulzer Paper
Technology.
Jean-Guy Sauvageau, Vice-President
Technology for Alliance Forest Products
Inc. reported as follows:“Excellent cooperation and support during project engineering, installation ofequipment, commissioning, start-up andoptimization made this project an experience to remember. Thanks to all employees involved, who worked «twogether» tomake this project a success. The collaboration was instrumental in the launching of the Donnacona project, whereupon Voith Sulzer Paper Technology was
also awarded the contract to supply asecond paper machine.”
Rebuild work on PM 5 started in late1996, and official start-up was on August
4, 1997. From the start, the press rooms
praised the quality of paper produced on
PM 5 after rebuild, and their satisfaction
increased as optimization proceeded.

Paper Machines

125

Fig. 1: Jacques Perrault,
Technical Manager
Alliance Forest Products.
Fig. 2: Dolbeau PM 5
Main data
Wire width 6425 mm
Trim width 5840 mm
Design speed 1200 m/min
Basis weight range 45-56 g/m 2
Products SCB and newsprint.

To quote from the Alliance 1997 Annual
Report, “Buyers are extremely satisfied
with the papers, which have been lavishly
praised by many customers.”
In November 1997 Alliance launched the“Eminence” brand, soon followed by“Eminence Plus”.
“Offering excellent printability, Eminancepapers have received a good market
acceptance and are highly praised bymany of our customers” said Pierre
Monahan, President and CEO of Alliance
Forest Products Inc.
This high praise notwithstanding, optimization continues as Alliance drives
toward better and better quality. One ofthe principal players in this project is
Jacques Perrault, well known in Canadian as well as international papermaking

2

technology circles. Let Jacques have thelast word on the machine:“Thanks to the ModuleJet dilution headbox, PM 5 has consistently produced
excellent dry weight profiles, as shownby 2-sigma spreads typically between
0.12 and 0.17 g/m 2 . Such a level of profile uniformity is clearly beyond what
could be achieved with a conventional
headbox. This was of prime importance,
considering the use of soft calenders.
Roll build and pressroom performancereflect these very good profiles.
Although the forming section is still being optimized, the sheet generally showsa ‘smile’ z-ash distribution, with basically no two-sidedness.
Paper machine runnability has been very
good because of very short web trans-

fers from the press and throughout thedryer section, the use of DuoStabilizer
boxes and vacuum rolls, as well as operating with very light draws. A clean operation of the DuoFormer CFD and the
DuoCentri press in addition to the use ofslotted screens in the stock system contribute to this strong performance“.
The Donnacona project team is almost
unchanged from that responsible for the
Dolbeau PM 5 rebuild. This was an excellent example of how well the Voith Sulzer
Paper Technology partners work «twogether». Although the major supply wasfrom Appleton, entire aggregates weredelivered from Middletown, Krefeld andHeidenheim, with significant components
from Brazil and Ravensburg. The successful integration of all these parts into
the machine reflected the successful
merging of the two companies.

26

Paper Machinery Divisions:

Corrugated medium and testliner –Visy Paper VP8
breaks the 1000 metres per minute barrier
One of the world’s fastest paper ma-

During its first 30 years of operation Visychines for testliner and corrugating

Industries’ activities concentrated on themedium has been installed at Visy

manufacture of corrugated cardboard

Paper in Brisbane, Australia. Built byboxes. The flagship Visy Board Packag-

Voith Sulzer Sao Paulo in 1996, theing Division is now the Australian market

machine produces corrugating medium

leader and operates some of the world’s

and testliner at basis weights frommost modern facilities.

113 to 275 g/m 2 .
The author:
Carlo Bigaran,
Production Manager,
Visy Paper, Australia

Visy Industries is especially committed
to recycling and the environment. In

Group History & Overview
Mel-

1990 the company won a prestigious

bourne, Australia in 1948, has grown toBanksia environmental award for its

become one of the world’s largest pri-recycling efforts in Australia.

Visy

Industries,

establishedinvately-owned paper recycling and pack-Some key data of Visy Paper VP8:
Maximum deckle at the pope reel : 2950 mm
Maximum production of the machine:
537 tonnes in 24 hours
Production off the winder: 511 tonnes in 24 hours
Maximum production rate: 23 t/hr on 150 g.

aging companies. Visy now employs

Visy Paper

more than 5000 people in Australia, New

Visy Paper is the paper making division

Zealand and the USA. Total manufactur-of Visy Industries. Its vision is to contin-

ing revenues exceed AUS $1.5 billion andually apply the latest technology tototal manufacturing assets exceed AUS

achieve world leadership in recycled$1.7 billion.

papermaking.

Paper Machines

27

Fig. 1: The Visy Paper 8 mill is situated on thebanks of the Brisbane River.

1

Originally established in 1980 to produce

expectations and can already claim to be

the latest technology in all of the facets

packaging paper for the Visy Board cor-among the fastest paper machines of itsof the recycling process with new and in-rugated cardboard box group, Visy Paper

type in the world.

novative ideas both for the paper making
process and the auxiliary services. The

has since built nine of some of theworld’s newest recycled paper mills –The mill is built in the shell of an old pow-

design of the paper machine itself, thesix in Australia and three in the USA.

er station situated on the banks of thesteam generation multi fuel boiler andTogether these machines produce more

Brisbane River. It was decided to restore

the water treatment facility are excellent

than 1.2 million tonnes of high perfor-

the existing landmark building, and only

examples of unique engineering applica-

mance 100% recycled packaging paper

demolish the internal building structure.

tions.

The aim was to develop the site into the

The Visy Paper 8 mill was completed ten

Of this, 750,000 tonnes are consumed byflagship for the entire Visy Group. The

months after construction began, twoVisy’s integrated box making operations

Visy project team was led by the mostweeks ahead of schedule and within bud-in Australia, New Zealand and the United

experienced managers and engineers

get. The project´s success is demon-States.

from the other Australian mills. Visy

strated by the achievements made in its

each year.

Paper is a unique company in that it

first two and half years of operation,

Visy Paper PM8

utilises “in-house” engineering and pro-which justifies the pioneering design ofLocated on Gibson Island in Brisbane,

ject management. This enables the com-the machine.

VPM8 was designed to produce a widepany to have complete control of therange of packaging paper at the fastest

project and also allows the experience

The Process

speeds in the world. As one of thegained during design and construction to

Waste paper collected from the urban

world’s technologically most advanced

be utilised in the operation of the plantforest of Australia’s cities is transported

paper recycling mills, VP8 was the win-

as well as future projects.

to the site by road transport and emptied
in the waste pit able to contain 2000

ner of a 1997 Engineering ExcellenceAward.

The location of the site, technical goals

tonnes. The unique process of loading a

as well as the environmental considera-

waste paper high density pulper is bySince the start up of the mill in 1996, thetions required input from all disciplines

crane and “orange peel design” grabble,

machine has operated beyond designof engineering. The new mill has utilised

each pick up weighing up to ten tonnes.

28

Fig. 2: Mill Manager Daryl Whithead (center,back row) and his team.

The water clarification in the plant uses
disk filters and then utilises dissolved air
flotation and sand filtration to remove alarge proportion of fillers/ash. This enables a cleaner furnish and water systemand permits reducing the fresh wateramount in the plant.
All the contaminants generated fromwaste paper collection are screened fromthe pulp stream and utilised as a fuelsource in the multi fuel boiler with directsavings in coal usage and elimination of
costs involved with land fill. The multi
fuel boilers generate 42 bar steam using
coal as the primary fuel and mill rejects,

2

The stock preparation then processes the

The press section incorporates a miniwood waste and even sewage treatment

waste paper with the priority being clean-press of 80 kN/m followed by a Jumbo

plant sludge as secondary fuel. Methaneliness and efficiency. Fractionation ispress at 220 kN/m. The third nip is agas produced by the effluent treatment

adopted with the short fibre fraction be-

NipcoFlex press loading to 1100 kN/m.

plant can be used as another fuel source

ing thickened and sent to the approachThis is a design for an easy conversion

by the boiler.

flow. The long fibre fraction is processed

to a second NipcoFlex in stage two of thevia coarse screening, low consistency

project.

The development of liner grades on the
CFD former and the expansion to thecentrifugal cleaners, fine screening, dispersion and refining prior to being sent

The dryer section consists of 52 dryers

higher g/m 2 and higher speeds involved

to the approach flow. The low consisten-with a single tier first section followed bynumerous hours of trials. The result is

cy cleaners in the stock preparation en-

a two tier dryer configuration. The dryers

the successful machine operation manu-

able the approach flow to be simplified toare bisected by a pond size press where

facturing paper at high quality and pro-exclude cleaners. The stock is de-aerated,

starch is added to enhance strength

duction rates far exceeding design fig-

screened and sent to the paper machine.

characteristics.

ures. The ultimate result was breaking

The paper machine uses a Voith Sulzer

The finishing section consists of winder

for 8 hours making 108 g/m 2 corrugated

DuoFormer CFD. This technology permit-

and automated reel handling and la-medium and averaging at 1015 m/min forted to exceed the previously known gap

belling, and conveying to the site reel

24 hours. Breaking the 1000 m/min bar-forming limit and increase basis weights

store. Over 50 % of the paper produced

rier for an extended period of continuous

to 275 g/m 2 . This is the highest basis

is sold to the export markets of Asia andproduction was a just reward for theweight manufactured on a gap former andthe Middle East.

efforts of all the personnel at VP8 in thethe world record by running 1020 m/min

confirms the flexibility of the machine.

two and half years of operation.

29

Paper Machinery Divisions:Tamil Nadu PM 2 –Newsprint from 100% bagasse
Tamil Nadu Newsprint and Papers Ltd.

mercial production of writing printing– popularly known as TNPL – started

paper and newsprint using sugarcane

commercial production of newsprint onbagasse as the major raw material. It

its new Paper Machine No. 2 from Janu-achieved the distinction of being theary 1996. The machine was supplied

world’s first mill to produce newsprint

jointly by Voith Sulzer Paper Technolo-

from bagasse in commercial scale.

gy and its licensee in India, Larsen and
The authors:
C.S. Panigrahi,
Larsen & Toubro Limited,
India;
without photo:
T.V.V. Satyanarayana,
General Manager
Tamil Nadu Newsprint andPapers Ltd.

Toubro Limited and has opened up new

Having tasted success – TNPL dared tovistas for newsprint making. The tech-

dream to make newsprint using 100%

nical brilliance of the design and quali-bagasse fibre and they embarked uponty of supplies were reflected in the ex-

an expansion project for doubling thecellent technological results achieved.

mill’s capacity in 1992 to 180,000 t p.a.,

The machine is designed to run withmaking TNPL the largest single-site inte-

100% bagasse furnish which is bothgrated paper mill in the world using

unique and unprecedented in history ofbagasse as the main raw material. The

newsprint making.

World Bank supported the expansion
project with a loan of US$ 75 Million. In

This paper aims to recount the successtheir search for the best ofachieved in this newsprint machinemachinery TNPL went global and finallyplant andwith particular reference to the technol-

the choice fell on Voith Sulzer Paper

ogy behind it.

Technology. The machine has a design
capacity of 400 tons/24 hrs. with design

Introduction

speed 1000 m/min and trim width

A small village on the Banks of river Cau-

6.6 meter. The machine configuration

very in the southern part of India has

was evolved by Voith Sulzer Paper Tech-become a place of pilgrimage for the Pa-

nology in close co-operation with TNPL

per Makers of the world. In 1985, theafter a large number of laboratory andmill Tamil Nadu Newsprint and Papers

pilot plant trial, to handle a weak furnish

Ltd (TNPL), located here started com-like bagasse.

30

tanously move fines and fillers to the

Machine Concept
The machine was equipped with a “Duo-TNPL PM 2 – design data

paper surface due to the active shear

Former CFD” Gap Former, DuoCentri-2

Product

Newsprint grades

forces.

FurnishBleached chemicalbagasse pulp – 60%
Mechanicalbagasse pulp – 40%

Press Section, “CombiRun” Dryer Section and a Hard Nip 4-Roll Calender
Stack. The machine incorporates highlevel of instrumentation and enables thePress and Dryer Section
The press section is of Duo-Centri-2
design. The first press nip is double felt-

operations to be monitored and con-

Production

384 tons at reeled, with additional press nips located attrolled through a state-of-the-art ABB

Trim width

6600 mmcircumference of a central roll. All free

Operating speed

850 m/min

Design speed

1000 m/min

paper draws have been avoided and theMaster Distributed Control System. The
DCS enables controlling the entire Paper
Machine, with help of visual display units

web is supported by Suction Roll after
the leaving the third nip. This ensures aclose draw between the Press and Dryer

which are available at a single location.
GapJet Headbox and CFD former

design ensures excellent runnability andSection. Due to runnability reasons, thehigh availability.

first two groups of Dryer Section is insingle tier arrangement with Suction

The Gapjet Headbox, in conjunction withthe corresponding DuoFormer, forms a

A Suction forming roll initiates drainage

Rolls. The next two groups are arranged

finely tuned, highly accurate sheet-form-

and formation of the two outer layer inin double tier manner. All dryers areing system. High availability of the ma-

DuoFormer CFD. Drainage is continued

equipped with Spoiler Bars to increasechine is guaranteed by Thermal stabiliza-

upto and beyond the immobilization

the drying capacity and optimise mois-

tion and good accessibility.

pointture profile.

by

the

subsequently

arrangedD-section with a curved suction box in
The DuoFormer CFD offers a wide range

the top wire and a formation box with

Start-up and Production Experienceof application with respect to grade, ba-

adjustable blades in the bottom wire. The

The start-up of the machine was in Sep-

sis weight and speed. It incorporates thealternating blade arrangement of thetember 1995 and in fact the first reelpositive attributes of roll and blade form-

D-Section helps in a uniform effect of

produced was of commercial quality.

ers and therefore combines the require-

shear forces through the web thickness.

With the help of highly experienced pa-

ments for optimum paper properties and

The formation blades prevent floccula-permakers of TNPL, Voith Sulzer Paper

ease of operation. Further more, its cleantion in the middle of web and simul-

Technology was able to fulfil the firstPaper Machines

31

Here too the use ofalternative raw materials pays off
More and more countries with a growing
Machine production (in 1000 t)

8

demand for paper, but limited timber resources, are using alternative furnishes

6

instead of this classical raw material.
Thanks to comprehensive experience,

4

Voith Sulzer Paper Technology is a welcome partner in this sector.

2
0

5
3
4
1
2
TNPL PM 2 – production data of first five months(Capacity utilisation low due to recession in IndianPaper Industry).

quality targets easily. It was one of thesmoothest start-ups of a machine of thissize and kind. History was made when
100% bagasse furnish was used for the
first time in the world to produce quality
newsprint in TNPL PM2.
The performance guarantee run was a
run-away success with fulfilment oftarget figures with respect to production,
machine efficiency, furnish, percentageash,moisture

and

paper

properties

eg. caliper profile, porocity, roughness
etc. The steam consumption achieved
was an incredible 1.33 kg steam/kg of
paper

and

power

consumption

was

498 kWH/ton of saleable paper.
When the country was looking for alternative raw materials to save its forest –TNPL has come out with an answer. The
countries with abundance of sugarcane
must be looking at TNPL with gratitude.
But TNPL – does not want to stop andbask in its glory. It has already set its
sights on building a bigger plant at
another site.

Complete paper mill for Egypt
Early in 1998 Voith Sulzer Paper Technology received an order from Quena
Newsprint Company for a complete
newsprint and printing / writing paper
machine line in Kous, Egypt. This order
was won against extremely tough global
competition following an internationaltender invitation. Decisive grounds forawarding the contract to Voith Sulzer
Paper Technology included outstandingreferences in newsprint and printing/writing paper machinery using bagasse,a difficult furnish. All the most advanced
Voith Sulzer Paper Technology components will be used in this new Quenaplant. For example, the latest version of
the ModuleJet headbox will ensure an extremely good basis weight cross-profile
with independently controllable fibreorientation profile. The state-of-the-art
DuoFormer CFD gapformer enables
active control of ash and fillers distribution in the Z-direction, and guarantees
optimal formation and runnability. The
machine will also be equipped withmodern NipcoFlex press technology and
TopDuoRun dryer section. Perfect paper
quality will furthermore be ensured by a
Speedsizer and tandem softcalender.

This paper machine, with daily capacity
400 tonnes, will thus be equipped withthe most advanced technology available
on the market at the present time.
Apart from the paper machine, the Voith
Sulzer Paper Technology scope of supply
includes the stock preparation line, approach flow section, whitewater system,
rejects handling, reel trimming, transportand packaging machinery. Chemicals
processing, piping and containers arealso included, together with process control systems, all drive gear and electricalcomponents. Start-up is scheduled forearly 1999.
First shoe press for graphical papers
using 100% Eucalyptus furnish
Voith Sulzer Paper Technology is alsodelivering the first NipcoFlex press forpapers made of 100% eucalyptus furnish. Customer is the Luis Antonio paper
mill in Sao Paulo, Brazil, a member ofthe Votorantim group.
Purpose of this rebuild is to raise theoperating speed of paper machine 1(rotogravure and offset printing paper)from 980 to 1200 m/min. Paper quality
will also be improved substantially withregard to basis weight, moisture content
and fibre orientation, together with better
formation and higher output.
Installation of the new NipcoFlex press
will include conversion of the former anddry section, and a Speedsizer will also be
installed. Commissioning is scheduled
for July 1999.

32

1

Paper Maschinery Divisions:

The new Tandem NipcoFlex Pressfor optimum paper properties

Until some years ago press sections forpaper machine in the world. The latest

fast graphical paper machines did not

development however is the Tandem

use shoe press technology. Since the

NipcoFlex Press, Fig. 1, which consists

first installation on PM5 in Perlen,of two, double-felted, straight throughSwitzerland in September 1994, there

shoe presses. It is designed for highis a growing demand for this technolo-

speed machines and optimum paper

gy. A further step towards high speed

properties.

and high efficiency was the DuoCentri
The authors:
Karl-Josef Böck, Dr. Thomas W. Elenz,
Paper Machinery Division Graphic

NipcoFlex Press (a 3-nip press with a

The first commercial Tandem NipcoFlex

shoe press in the third nip) on PM 53 at

Presses for highest production speeds

Braviken, Sweden, now the fastest

will start in autumn 1999.

Paper Machines

33

Fig. 1: Tandem NipcoFlex Press.
Fig. 2: Draw between press and dryer section fornewsprint and SC paper.
Fig. 3: Tandem NipcoFlex Press with steam box,
splash guards and exhaust points.

What were the driving forces for this2

development ?
5higher efficiency and improved paper
properties were the driving forces forthis development. With higher speeds,
the draw between press and dryer section and, therefore, the tension in thepaper is getting higher. However, reducing the safety margin between the wet

Tension [%]The demand for faster machines with

SC

4
3

N

rint
ewsp

100%

DIP
s
coFlex Pres
Tandem Nip
lts
fe
4

2
DuoCentri Press
1

strength of the paper and the sheet ten1000

sion, the risk of breaks and their number
increases. Until recently, this was the1500
Speed [m/min]

2000

major obstacle towards higher machine
speeds. Since the Tandem NipcoFlex

press sections need approx. 1.5% higher

twoPress is a configuration without smoothdraw, Fig. 2. As further advantages of theFig. 3. Threading will be done machine-roll surfaces, it overcomes this bottle-

closed draw configuration we expect lesswide from the wire section to the dryer

neck. During pilot trials it was found that

paper breaks, fast paper threading, nosection using suction rolls, without open

thedoctoring at center roll and high speed

draw in the press. The NipcoFlex rollpotential.

(shoe) is in top position while the heav-

Tandem NipcoFlex Press with four

felts (no open draw) could be operated –due to the dryer section – using a draw

straight

throughshoepresses,ier Nipco P roll (backing roll) is locatedbetween press and dryer section of 1.5%

What are the key components ?

in bottom position. In front of the two

to 3.5%. In comparison, conventional

Characteristic of this press section arepresses the DuoSteam blow box for3

34

Fig. 4: Felt conditioning.
Fig. 5: Dryness after press for different paper
grades
DuoCentri NipcoFlex
Tandem NipcoFlex
4

5

SC
LP

HP
LP

ULWC

Dryness [%]DuoCleaner

woodfreeNewsprint

50

1,700
8

40

1,700 1,700
15
30

1,200
15

1,050
15

850
15

v [m/min]Filler [%]Uhle box
0
20

0

40

Test results

60
Basis weight g/m2

100

80

moisture profiling and increasing dry-cross profiles. Besides the Uhle boxes

For newsprint and SC grades the Tandem

ness can be located. The boxes are

and water showers the successful Duo-

NipcoFlex Press reaches the same dry-swiveled away during web threading.

Cleaner is integral part of every felt run

ness level as the well known DuoCentri

to keep the felt open and improve overall

NipcoFlex Press. A minor rewetting how-

Are there any special features for highefficiency, Fig. 4. The traversing rotor

ever is inevitable at double felted nips.

speed applications ?

nozzle – using only 2 liters of water per

Therefore, the DuoCentri NipcoFlex Press

Yes: As mentioned, there are suction

minute – already in the first production

reaches the highest dryness for ULWC

rolls for a controlled and safe paper run.

machine proved that it has great advan-with the extreme low basis weight ofThis is of extreme importance after thetages.

26 g/m 2 . Since the maximum allowablenip, where top and bottom felts separate.

draw of this light paper grade is the bot-

After each shoe press we provide at thisWhat are the test results and where cantle neck in press sections with a center

point of separation a suction roll. Sheetit be applied to ?

roll, we expect that the DuoCentri Nipco-stabilizers support the sheet run if nec-

Important requirements on a press sec-

Flex Press will not reach the high pro-essary. Another feature are the splash

tion are a high bulk paper at highest pos-duction speeds of a Tandem NipcoFlex

guards that completely enclose the press

sible dryness with no twosidedness. Two

Press.

For

rolls (NipcoFlex and Nipco P). In addi-

shoepresses in a row, both double felted,

60 g/m 2

the Tandem NipcoFlex presstion, low pressure exhaust systems are

obviously have the potential to fulfil

opens up all its advantages. In addition,

installed to prevent mist and dust. Of

these requirements. We have tested dif-the difference in dryness after the press

extreme importance is a maximum dewa-

ferent paper grades. In some cases high-between the two configurations is be-tering in the nip. The water passes fromest possible dryness, in others highest

coming more pronounced with increas-

the paper through the felt and is slung

possibleThe

ing basis weight. For a woodfree 85 g/m 2

off by centrifugal forces into splash

achieved dryness as a function of basis

coating base paper the Tandem Nipco-

guards. Felt conditioning is a further

weight is shown in Fig. 5. The corre-

Flex Press reaches already 2% more dry-important topic. It is significant for a

sponding filler content and speed areness than the DuoCentri NipcoFlex Press.

long felt

also listed.

life as for excellent moisture

bulk

was

the

target.

basis

weights

exceedingPaper Machines

35

Fig. 6: Inter-relationsship of press and calenderwork.
Fig. 7: Twosidedness.
6

7
Bendtsen
40
500
700 kN/m
118 ÷ 122 µm
650 ÷ 750 ml/min
47 ÷ 49 %Thickness
Roughness
Dryness

Twosidedness [%]Tandem NipcoFlex

Cobb oil
30
PPS
20

10
Soft Calender200 ÷ 250 kN/m
> 104 µm
150 ÷ 220 ml/min

Thickness
Roughness

0
DuoCentri NipcoFlex
with 3 felts

Tandem NipcoFlex
with Transbelt
with 4 felts

Fig. 6 shows in more detail the inter-and yields higher smoothness of theadvantage,

relationship between the press and thepaper surface.

weights (ULWC), despite a minor rewet-

for

low

basis

ting. At medium basis weights (news-

calender work for a bulk sensitive woodg/m 2 ).

especially

The market

The two double felted shoe presses are

print, SC), the low twosidedness, re-often requires a specific bulk of 1.3

dewatering nearly symmetrically to top

duced number of breaks and the speed(thickness 104 micron) at a Bendtsen

and bottom side. After extensive trials

potential are very advantageous. At highroughness in the range of 150 towith various felt suppliers and a further

basis weights the Tandem NipcoFlex

220 ml/min. The required specific bulk

development of the felt design thePress allows, aside from the already

was achieved by the Tandem NipcoFlex

twosidedness in Bendtsen, PPS and oil

mentioned benefits, much higher dry-Press of the pilot installation with linear

absorption were seen to be plus minus

ness. In summary, the Tandem NipcoFlex

loads of 500 to 700 kN/m. Since bothsome percent and confirm the expecta-

Press, with four felts and two shoe

paper sides have the same roughness

tions, Fig. 7. The application of a transfer

presses, is, because of all the mentioned

after the press, the two soft calenders

belt instead of a bottom felt in theadvantages, in many applications thecan both be loaded with approx. 200 tosecond press results as expected in amost desirable and most economical

250 kN/m at 150°C.

distinct deterioration with respect tosolution:

twosidedness due to the different sur-I high dry content and high specificfaces and dewatering in one direction

bulk with two NipcoFlex presses

free copy paper (80Considering

theentireproduction

process, the optimum combination, for

only.

I four felts for minimal twosidedness
I low paper expansion

this specific furnish, was a paper thick-I suction rolls for controlled and safe

ness of 120 micron with 700 ml/min

Conclusion

Bendtsen at high dryness after press that

The Tandem NipcoFlex Press is part ofwas calendered to the target of 150 tomany linerboard machines since years.

220 ml/min at 104 micron. Generally, a

In the meantime, this concept was devel-

With the new Tandem NipcoFlex Press

lower nipload of the Tandem NipcoFlex

oped further for printing & writing

Voith Sulzer will set new benchmarks in

Press has the advantage of higher bulk

grades. The drawless sheet run is a big

speed, efficiency and paper quality.

web run, short threading time.

36

Paper Machinery Divisions:

The packaging paper machine beyond 2000
New trends in the corrugating businessthe company policy of these enterprises.

were driving forces to develop a liner

This development brought about several

and medium paper machine concept fortrends in the corrugating business.

the future. The trend towards lighter
paper grades will allow to overcome

Tendency

the 1000 m/min limit without restraints

In order to find a concept for the futurein quality.

we think we have to look over the edgeof Voith Sulzer Paper Technology deliv-

The author:
Erich Brunnauer,
Paper Machinery Division
Board and Packaging

Well known limits of today will be de-ery. We have to study the main trends in

scribed and solutions will be discussed

the corrugating business, which will af-

to increase machine speed at of higher

fect the paper machine concept for the

productivity and better quality.

near future. The most significant ones are:I reduction of costs

Current Situation

I reduction of weight

Corrugated board has a respectable mar-

I supply chain management

ket share of more than 70% of all trans-

I development of logistic concepts

port packaging. The market can be divid-

I more technology in corrugatinged into recycling papers, such as test-

process.

liner and medium (70%), and virgin fiber
based kraftliner and fluting (30%).

New Flute Types
Taking a closer look at corrugated medi-

A shift towards recycling paper can beum, one can see a new generation ofnoticed. Both, recycling paper and virginflute profiles coming-up. Nowadays, thefiber containing papers with huge forests

majority of profiles produced oin the cor-

as renewable resources perfectly meetrugators are of the A, C, B and D type.

the concept of sustainable economy.

These profiles are well known and used
for boxes with high strength potential.

In recent years dramatic developments

Besides the conventional profiles there

have taken place in the packaging indus-

already now is a small market for a new

try. Apart from economic aspects, eco-

generation: the E, F and N profiles, which

logical considerations have become aare much smaller in height and used for

major driving force. The opening of sev-

low basis weight paper (Fig. 1). If youeral borders in Europe permitted a con-compare the height of the flute type A

centration of smaller companies to form

with N, you can see that there is a factor

large enterprises. As a result, there wasof 9-10 between. The market for thesea shift from a regional to an international

low grammage papers is expected toapproach, which had a strong impact ongrow fast in the next years.

Paper Machines

37

Fig. 1: A new generation of flute profiles.
Fig. 2: A new generation of flute design –Wave Flute: Isowell-B– eye catching effect– higher compression strength– better scoring characteristics.

New Flute Design

12

created on the Japanese market: the socode average average
spacing height
(mm)
(mm)

called wave flute. It has a corrugated

A

8.7

4.7

C

7.3

3.8

B

6.0

2.8

two-dimensional wave design which is

D

4.5

2.1

shown in Fig. 3.

E

3.3

1.4

F

2.6

0.75

N

1.8

0.55

A few years ago, a new flute design was

structure like the conventional flute. But,

shape
30 mm

what is new, there is a second wave
across the whole surface. The result is a2.75 mm

6.6 mm

It is produced on a single facer corrugating machine so that you can see the interesting wave design. This design allows a reduction of basis weight. ThereThis short study of the trends in the cor-

Limits today

are 14 corrugators in operation in Japanrugating business shows that one impor-

If we look at the packaging paper ma-

and in the US. The next start-up will betant trend will significantly influencechines of today, most of the machines

in Europe.

paper production in future: the reduction

are limited in speed: The main limitingof the basis weight (Fig. 5).

factors are sheet forming on fourdriniers
and sizing with pond type size presses,

Due to environmental regulations, the re-especially for testliner and medium.

strictions imposed by them and costs,

Trend of basis weight for light weight

the average basis weight of corrugatedpaper…

board and thus of liner and medium

yesterday

127-140 g/m 2

Tomorrow’s concept

grades has been reduced. This trend will

today

90-115 g/m 2

The year when 70 g/m 2 paper has to be

90 g/m 2

produced is coming up faster than every-

continue in the future and will be sup-tomorrow

60-

body wants to believe. The effect on

ported by technical and technological developments in the paper and corrugating…and the effect on PM productivity

industry.

1000 m/min x 100 g/m 2 = 144 t/day·m
1000 m/min x 70 g/m 2 = 101 t/day·m

Today, a PM produces 100 g/m 2 and is1500 m/min x 70 g/m 2 = 151 t/day·mlimited to 1000 m/min, that is a specificproduction of 144 t/min*m. Tomorrow,

Lower Basis Weight
The main reasons for the production of

paper machine productivity is obvious.

Yesterday,theindustrytalkedone will have to produce 70 g/m 2 – theabout 127

g/m 2 .

still

Today, Voith Sulzer

specific production will thus be 30%

Paper Technology gap formers produce

lower, but fixed costs will remain the

I strong market demand

90 g/m 2 packaging grades and this de-same.

I new life cycles

velopment will go on. Tomorrow 60 g/m 2

I progress in flexo-print technology

paper will be produced and the market

The only way out is to increase the pro-

I new flute types and designs.

for this grammage will grow.

duction speed. 1500 m/min will bringlighter paper are:

38

forming in future

3

back the productivity level of today.

With two ply concepts a 10-20% higher

the optimal solution. For White Top Liner

Voith Sulzer Paper Technology gives you

burst can be achieved.

thethe technology to reach this goal.

DuoFormer

Top

gives

optimum

results. For liner the DuoFormer Top
In order not to loose this advantage in

together with the DuoFormer Base offer

Maximum Strength

the future, Voith Sulzer Paper Technology

the advantage of two ply forming. This is

Unfortunately the quality of secondary

has been concentrating on research andthe first time in the history of Voith

fibers will not become better in future. A

development for a new two ply forming

Sulzer Paper Technology that a two-gap

maximum gain in strength therefore hasconcept which allows production far

former concept is offered for producing

to be an important goal in the wet end.

beyond 1000 m/min.

both the base and the top ply for packaging grades.

Today an average corrugated medium

Forming in Futuremachine has a fourdrinier – tomorrow,

With the new gap former generation for

Pressing in Future

an average machine will have a gap

board and packaging papers – the Duo-

After the revolution of the shoe-press

former. Especially for liner burst is very

Former Base and DuoFormer Top – thetechnology in the last 15 years we still

important, that is why today a configura-

Paper Machine Division Board and Pack-

need evolution: If the speed for pack-tion using two fourdriniers is given pref-aging has developed units that are excel-

aging paper machines will come up toerence over single ply forming.

lently suited to meet the demands of the1500 m/min then we need:future (Fig. 3).
I a higher press impulse to get

The reasons for higher burst are:
These units are the standard concept for

I maximum dry content

liner and medium grades: For medium

I a uniform densification in z-direction

I lower z-orientation

grades the DuoFormer Base with a one-is the key for highest strength values.

I in addition, the consistency can belayer headbox, for liner grades the Duo-I more perfect sheet forming: 50 g/m 2
more perfect than 100 g/m 2

reduced.

Former Base with a two-layer headbox is

These are the reasons why the pressurePaper Machines

39

Fig. 3: A forming concept for the future ...
available today.
Fig. 4: Evolution of shoe press technology– higher press impuls– maximum dry content– uniform densification in z-direction– higher strength improvements– lower risk of crushing– higher life time of felts and sleeve.
Fig. 5: How to overcome the 1000 m/min speed
limit?
4

5
Cerestar Voith Sulzer Paper Technology trials on Medium grades
improvement

size press

Speedsizer

CMT

low basis weight

SCT
uhle box / felt
dewatering

nip dewateringpressing in future

sizing in futurev

curve should be like the one shown inwhether enough starch can be introduced

Speedsizer gave some very promising re-Fig. 4 for the entire press section:

into the paper with the same results

sults. With basis weights up to 120-130

as with a size press. Tests were per-g/m 2

I higher strength improvement

formed on liner grades: furnish wasachieved with a Speedsizer and CMT im-

I lower risk of crushing

100% secondary fiber. The most impor-provement is as good as with a size

I and higher life time of felt and sleeve.

tant quality test criteria for liner arepress (Fig. 5). With very low viscosity

burst and SCT.

starch it might be possible to get fullRoll presses, with their sharp pressure

fullpenetration

can

also

be

penetration with higher basis weights, as

curves and high maximum pressures,

The results clearly show that with thewell. This means that for high speed pro-have major disadvantages. The Tandem

Speedsizer you can get the same burst

duction of corrugated medium grades the

NipcoFlex is a step in the right direction.

and SCT performance as with a conven-

Speedsizer is the solution for: sizing intional pond type size press when using

future. Two references with Speedsizer in

Sizing in Future

light weight paper. For high speed test-

operation for testliner and corrugatedBut, there another limiting factor for highliner machines the Speedsizer will be

medium underline this trend.

speed production – the size press. Voith

used for sizing in future.

Sulzer Paper Technology has put a focus

Conclusions

on this topic and entered into a strategic

In the case of corrugated medium, theNew concepts in the wet end and theco-operation with Cerestar. The goal of

situation is somewhat more complicatedtrend towards lighter paper grades will

research & development was to find out

corrugated medium. For good CMT val-

allow to overcome the 1000 m/min with-more

performance.

ues full penetration to the middle of theout restraints in quality. Voith Sulzer

Where are its limits? And what is theabout

Speedsizer

paper is a must, otherwise the paper willoffers a concept for a high output / effi-

effect on burst, SCT and CMT? It is

split up into two layers. With the size

ciency / quality paper machine and opens

no secret that the Speedsizer can runpress CMT and SCT improvement is no

the door for competitive production offaster than 1000 m/min. The question isquestion.

packaging grades beyond 2000!

Tests

performed

with

the

40

Paper Machinery Divisions:

The board machine beyond 2000
Board machines for high capacity pro-

Increased production and product quality

duction are today limited by design.

influence these factors in the opposite

These well known limits are being de-direction. For a machine supplier it isscribed and solutions are brought for-therefore necessary to help our cus-ward to increase machine speed under

tomers keep a balance between the trend

aspects of higher productivity and bet-

factors.

ter quality.
Voith Sulzer Paper Technology is conThe author:
Alexander Wassermann,
Paper Machinery Division
Board and Packaging

stantly developing new and adapted maIntroductionchine concepts with higher production

Regional differences in market require-

output per meter width of machine. Thisments influence strategic decisions ofpaper focuses on the possibilities of de-board producers. Disregarding this di-signing a board machine in respect toversity we can find general trends whichhigh output, high efficiency and highare not only true in the board- but

quality.

throughout the paper industry (Fig. 1).
The requirements can be derived from
These trends can be summarised as

two basic functions (Fig. 2) which are:follows:

I Transportation of Goods

I Reduce Production Costs

I Transportation of Information.

I Increase Production
I Increase Product Quality.

On the one hand stiffness in CD direction
is required which depends mainly on the

Reducing the production costs is only

bulk or density of the product. This ispossible by effectively controlling:

mainly influenced by raw material choice

I Raw Materials

and machine concept. On the other hand

I Utilities (Steam, Electricity and Water)

the surface needs to be smooth and

I Mill Productivity.

glossy for best printing results. In this1

2
Reduce production costs

functionrequirements

transport stiffnessof goods
raw material

utility costs

dependency parameterbulk

productivity

increasing machine speed
and quality demands

transport printability smoothnessofgloss
informationrawmaterials
machineconcept
coating
calenderingPaper Machines

41

Fig. 1: Trends in board production.
Fig. 2: Folding boxboard – functional
requirements.
Figs. 3 and 4: State of the art board machine andits limitations.
3

4

Wire section– Dewatering
length– Profile quality– Formation

Drying section– Cylinder drying– Sheet shrinkage– Yankee efficiency

Press section– Loss of bulk
– Open draw

Coating– Airknife speed
limitcase coating and calendering are thewill increase considerably and huge wire

comparable lower evaporation rates as indominating parameters to achieve thesections will be necessary. Good andother paper grades. Although new con-desired results.

stable profiles will be more difficult to

cepts are being developed to reduce theachieve on fourdriniers. The basis weightbuilding length as well as the required

Limits todayof the individual plies needs to be re-energy input, it is still matter of fact that

Considering waste paper as furnish we

duced

drying cylinder sections will be the major

are experiencing throughout all markets

formation (Fig. 3).

to reach thenecessary good

drying method well beyond the turn ofthe century (Fig. 4).

decreasing fibre quality which leads toreduced strength properties such as

Press Section

stiffness for example. Virgin fibre costs

In the press most board machines today

Double-tier drying sections have the dis-are considerably higher than for waste

still use straight through roll presses inadvantage of non restraint drying which

paper and naturally the board producers

most positions. The nips can be double

leads to shrinkage effects such as rough-for Folding Box Board seek new tech-or single felted, suction presses are also

ness increase or MD tensile decrease at

nologies for reducing basis weight at

common. The mayor drawback of such a

the web edges.

equal stiffness values.

press is however the loss of bulk whenseveral roll presses follow each other.

The replacement of the nowadays espe-

Wire Section

Also open draws lead to increased

cially in Europe successful Yankee cylin-

To reach the desired stiffness targets it

MD/CD stiffness ratio or in other words

der will be a priority task. The benefits ofis necessary to use several plies in thelower CD stiffness which is not accept-

the “M.G.” are still eminent where highforming area to structure the sheet ac-able (Fig. 3).

board surface quality requirements andlow raw material characteristics demandcording to the specific advantages of different raw materials on strength proper-

Drying Section

for a gentle smoothing equipment. In-

ties. Multi-fourdinier forming technology

The board machine of today is easily

creasing machine speeds will reduce theis state of the art, however limits can berecognised by its already extensive dry-advantages and runnability problems willseen at higher speeds: Drainage length

ing sections which are necessary due tomake a substitute necessary.

42Fig. 5: Modern concept for multiply board
machine.
Fig. 6: Tandem NipcoFlex press for board
machine.

The top ply can be produced on the last

5
DuoFormer Base

3x DuoFormer Top

DuoFormer Top as shown in this designin case of “top on top” or on the DuoFormer Base in case of a “top on bottom”
configuration.
A two layer headbox in the filler ply gives
flexibility in furnish distribution whenback layer

2x filler

under layer

top layer

6

producing white back triplex grades.
This concept eliminates speed barriers
and preserves the flexibility of today’s
multi-foudrinier layouts. The good formation capabilities of the Voith Sulzer
Paper Technology gapformer family introduces two immediate benefits:
In the outer plies better furnish quality
and lower concentration gives higher
tensile strength. In the middle plies it ispossible to run at higher concentrations
than today and still reach the required
formation levels. This produces a bulkier
sheet.
Both benefits together result in increased

Coating Section

a multiply/multilayer wetend of a board

stiffness properties or at same stiffness

In the coating section the airknife is wellmachine (Fig. 5).

levels in a reduced basis weight of the

known for its excellent covering abilities
however it is limited in speed (Fig. 4).

product.
A combination of a DuoFormer Base as
the back ply and three DuoFormer Top

The second feature is the two sided de-for the filler ply the under ply and the top

watering which gives

Tomorrow’s concept

ply is a flexible solution for multiply

I controllable fines and ash distribution

Wire Section

grades such as GD or GC and of course

The new generation of Voith Sulzer Paper

liquid packaging.

Technology formers for Board and Pack-in z-direction
I short forming length andI with different wrap angles any furnish

aging grades – the DuoFormer Base and

The design can be adapted for various

and consistency requirements can be

the DuoFormer Top – can be combined in

raw materials and dewatering capacities.

met.

Paper Machines

43

Fig. 7: Dryer section for fast running board
machines.

Press Section

7

Depending on maximum basis weights
run on the board machine it will be pos-CC

sible to reduce the amount of press felts

CC

to three from today usually five to six
when using a Tandem NipcoFlex Press aspressshown in Fig. 6. This concept can handle

coatersingle-tierfor runability

high amounts of water, has low peak nip

single-tieragainst shrinkage

double-tierfor curl control

cooling aheadof coatingpressures which eliminate the danger of
web crushing and retain bulk.
Single-tier groups are introduced fortion systems and a combination of rod

A smooth roll cover against a felted

runnability

reduction.

and blade metering elements. Important

NipcoFlex shoe press in last position

Double-tier groups control curl tenden-for outstanding coating results is the re-ensures the required smoothness of thecies. Cooling cylinders ahead of coating

duction of the sheet temperature ahead

baseboard on top side. As the dwell time

reduce web temperature. Surface sizingof the coating stations and the reel. Thisis longer in a NipcoFlex nip the smooth-is sometimes an issue in board produc-

ensures low coating colour temperatureness can be assured even at higher

tion depending on fibre quality and spe-and eliminates stress induction into themachine speeds. However depending oncific surface strength properties re-sheet due to temperature gradients in thefurnish and maximum basis weight, a rollquired. A film application of starch with arolls.

press needs to be installed ahead of the

speedsizer ensures an even sizing profile

shoe presses.

and reduces the amount of water brought

Conclusions

into the sheet. This shortens the length

This short description of the board

Drying Section, Coating and Calenderingof the afterdryer section. An additional

machine beyond 2000 shows possible

As already mentioned cylinder drying will

benefit is the low nip load in speedsizers

solutions in a combination of provenstill be up to date for the next decade,which retains bulk levels better thanmachinery elements. It leads to a Voithespecially considering the low energy

pond type size presses.

Sulzerandshrinkage

Paper

Technology

visionfor

future production plants as summarised:costs of steam as energy source. At increased machine speeds it will be impor-Surface smoothness is achieved in atant to stabilise the web as it is known

combination of hardnip and softnip cal-

The high capacity boardmachinefrom fast running paper machines forendering using the effects of temperaturebasis weight range

graphical papers.

and moisture gradients. This technology

wire width

has already proven that it is possible tooperating speed

160-400 g/m 2≤ 10.5 m
600 -1000 m/min≤ 3000 t/d

In a board machine curl tendencies needachieve the expected smoothness andmax. production

to be controlled which is achieved bygloss at bulk levels comparable to those

Products: Coated Multiply Board

separating the heating circuits for top

of Yankee cylinder machines.

– Duplex-, Triplex-Board– Liquid Packaging and Folding Box

and bottom cylinder groups in the main
evaporation zone. This leads to a designThe

onlinecoatersectionwillbe

as shown in Fig. 7.

equipped with JetFlow F coating applica-

Board– Gypsum Board.

44

1

Finishing Division:

TORO TD – graduation with honours
As already reported in Twogether, theVoith Sulzer Finishing Division has developed a new winder concept known as
TORO TD. Fig. 1 shows the layout of thismachine.

The author:
Dirk Cramer,
Finishing Division

An air relief system is used in the TORO
TD concept for keeping nip loads within
permissible limits to prevent damage. Air
entrainment during winding – a technological drawback of conventional winders
with air relief – is eliminated by the innovative web travel layout.
The main features of this machine arethat both nips can be relieved and thatthe well proven two-drum winder principle is retained. Fig. 2 explains the operating principle of the TORO TD with air
relief system.
With a rewind diameter of 1500 mm, thenip loads developed in a conventional
cutter would reach about 11.5 kN/m. Depending on paper grade, this would cause
crepe wrinkles or shiner zones due tolongitudinal displacement and unfavourable hardness distribution as a functionof winding diameter.
Thanks to the T-Air relief system, the desired nip load variation over the diameter
range can be preselected. For example

3.5 kN/m at the core, then slightly reducing until the diameter reaches 500 mm, afterwards rising to 5 kN/m at the periphery.
To comply with these settings, the T-Air
system comes into play after the winding
diameter reaches about 700 mm. Thismeans that nip loads can be adjusted precisely to suit paper quality requirements.
As a comparison, Fig. 3 shows the situation with a two drum winder where only
the second drum is rubber covered. Although this ensures that with equal loading the effective nip force on drum 2 remains within acceptable limits, the force
on drum 1 is still over 11 kN/m. Anotherdrawback is that relieving the second nip
also applies during winding, whereas nip
loading should be higher in order to generate the necessary winding hardness inthe core area. This shows one of themain advantages of the Toro concept: nip
relief does not come into play until actually needed.
What is the effect of air relief on winding
hardness? To answer this question, tests
were conducted on the Krefeld laboratory
test rig.
In Fig. 4 the Smith hardness characteristics with and without air relief are plotted
over winding diameter.

Finishing

45

Fig. 3: Nip loads at two drum winder with soft
covered drum #2.
Fig. 1: Toro TD with air relief system.
Fig. 4: Smith hardness without/with air relief
system.

Fig. 2: Nip loads at two drum winder.
theoretical nip load
nip load by rider roll
air relief system
resulting nip load.

Fig. 5: Smith hardness with/without air.
Fig. 6: Paper web travel at DuoRoller side #2.

2

This clearly shows that with conventional
winders, hardness rises after the diameter reaches about 900 mm. The T-Air
relief system prevents this undesirable
effect, as demonstrated by the interesting
test shown in Fig. 5.

3
12

12

10

10
Nip load kN/m

Nip load kN/m

8
6
4
2

8
6
drum#2

4
2

0
-2
100

drum#1

0
100

500
900
1300 1500
Rewind diameter mm

5
240

240

230

230

220

without
T-Air

210
200

with T-Air

Smith hardness

Smith hardness

4

500
900
1300 1500
Rewind diameter mm

220
210
200
air
190

190

on

air on
180
200

6

600
1000
Rewind diameter mm

1400

180
200

off

600
1000
Rewind diameter mm

1400

In this case air relief was activated at a
winding diameter of 800 mm and shut
down again when the diameter reached1100 mm. Clearly discernible is the resultant winding hardness trough – an eminent demonstration of how effective the
T-Air relief system is.
During market introduction of the TORO
TD, the question was often asked whether
the new web travel layout raised any drive
problems compared with conventional
systems. Without going into details, theanswer is very clearly no. Fig. 6 shows
the second side of a DuoRoller – a typewhich has been used very successfully
for several years now. As in the TORO TD
system, the web runs over both drums,
and no drive regulation or winding hardness control problems have ever arisenwith any DuoRollers.
Another feature of the TORO TD systemis the rubber covered drum No. 1 (Fig. 7).
The purpose of this relatively hard rubber
cover (65-70 Shore A) is not to reduce
the specific nip load – that is the task of
the air relief system. With impermeable
paper grades (high-gloss and coated papers), the boundary air must be prevented from being entrained into the roll andfrom building-up in front of nip No. 2.
That is why the first drum is rubber covered, thus mating the surface profile withthat of the paper rolls and closing nip

46

Fig. 7: Influence of rubber cover at drum #1.
Fig. 8: Peripheral forces at TORO TD.
Fig. 9: Rubber cover of rider roll.

Fig. 12: TORO Combi for Lang Papier.

Fig. 10: TORO TD, automatical roll set change.

Fig. 13: TORO Combi for Lang Papier,Smith hardness with air relief system.

Fig. 11: TORO Combi for Lang Papier,two drum mode.

Fig. 14: Control system TORO Tronic.

7

8

air

without
rubber
cover

9
TW

with
rubber
cover

F BW
F2
F1

T

higherpressure

F2

TW

F1

T

10

clamping device

perforating devicelowerpressure

11

cut
positionglueing nozzles

No. 1 to prevent air entrainment almost
completely.
This technique is also used successfullyin the Sirius winding system.
With high-gloss or coated papers – particularly for rotogravure printing – it isvery important to ensure adequate hard
winding in the core area during winding.
This prevents damage occurring near thecore – so called core bursts – during
unwinding on the printing press. So far
single drum winders with center driveson each station have been used for thispurpose. With the TORO TD system adriven rider/loading roll ensures optimum
winding hardness. The loading roll is
working as follows:
I The high initial press force of the loading roll is used for diverting peripheral
forces into the paper reel (Fig. 8).
I With increasing reel diameter, theloading roll pressure decreases andthe drive power is reduced accordingly.

I The loading roll is rubber cover, whichbrings two advantages:– better diversion of peripheral forces
into the paper roll
– the rubber cover of the loading rollallows to an appropriate extent forchanges in winding reel diameter(Fig. 9).
Apart from good winding quality, optimal
productivity is of course an absolutemust. To this purpose the following
automation possibilities are available:

47

12

I Automatic roll changing
Standstill splicing (e.g. end-to-end)
Low speed flying splice
I Automatic slitter positioning
I Automatic roll set change
I Web end glueing.
Fig. 10 shows the TORO TD components
required for automatic roll set changewith web end glueing.
The well-tried perforation system is takenover here from the DuoRollers.
So much for design aspects, but what
about practical experience? Since August
1998, rolls have been wound at Lang
Papier using the new TORO Combi system in two drum mode (Figs. 11 and 12).
The support roll system went into service
at the end of November 1998.

13

In two drum mode, some of the featuresdescribed above are included. Air relief
ensures that the SC grade paper (Janus
calendered) is wound perfectly without
any faults. The rubber covered rider rollprevents any air entrainment, and the soft
covered drums ensure well-dosed application of pressing forces. The technological results with regard to product quality
meet expectations in full.
Fig.13 shows the Smith hardness of rotogravure printing paper as a function ofwinding diameter.
As desired, the hardness decreases
slightly as winding diameter increases.
The wound-in stretch rate is 1.9% at thecore and 1.5% at the periphery, which isideal for this grade of paper.
Another advantage is how the TORO
winder characteristics correct faulty

paper rolls from other sources – simply
by rewinding them.
The TORO TD system is controlled by the
newly developed TORO Tronic software.
This was developed according to thewell-proven principle “as little as possible is enough” – and the result is an uncomplicated, user-friendly control system.
SummaryThis technical development by the Voith
Sulzer Finishing Division has proved itself outstandingly at Lang Papier. Admittedly there were teething troubles – butwith such an innovative design and control concept, this is hardly surprising.
As mentioned above, the support rollsystem went into service at the end of
November 1998, and we look forward to
publishing an equally gratifying operating
report in due course.
14240

Smith hardness

220
200
180
160
140
120
100

0

200 400 600 800 1000 1200 1400
Rewind diameter mm

48

Research and Development:

Image analysis in headbox development
One of the most critical tasks in head-

Optical methods without physical contact

box development is flow configuration

give superior results and are much easier

analysis. This particularly applies toto handle than if flow sensors are used.

surface analysis of the headbox jet

The main advantage lies in better quan-flow, which in fast-running paper ma-tification and more reliable results.

chines can reach speeds of 100 km/h or
more.

Furthermore, contactless measurement
can also be used for stock suspensions

We have developed measuring tech-where sensors would be unsuitable.

niques and analysis software enabling
precise flow assessment at such veloci-Flowmechanisms

significantly

affectties. As a result, this process know-how

technological characteristics and productis available for advanced headbox

quality, particularly during sheet forma-development.

tion in the GapFormer. Taken together
with other data, they give a comprehen-

The authors:
Wolfgang Ruf,
Hans Loser,
Paper Machinery Division
Graphic

Digital photography has made enormous

sive picture of hydraulic mechanisms

progress in recent years, and powerful

within the headbox. By combining andsoftware is now available for image

correlating this flow data with sheet for-analysis. This technology is particularly

mation results both in pilot tests andsuitable for processing large quantities

during production, a better and moreof digital data, such as from modern

rapid insight is gained into process

high-speed video cameras at up to 2000

mechanisms as a whole. This is indis-

images per second.

pensable for:

Voith Sulzer Paper Technology’s R&D

I Optimal adaptation to specificdivision in Heidenheim makes intensive

1High-speed
cameraDigitalcameraVideosourcecustomer needs

use of this technology among others forheadbox development. The complex task

I Efficient customer service and supportof adapting it to meet our specific needs
CD ROM

Disk

Video tapehas been solved by a team of headbox
development engineers, measuring sys-

I Development of new headbox
concepts.

tem specialists and software programmers. As a result, data from various digi-

The two image analysis methods mainly

tal image sources (see Fig. 1) can now

used are as follows:

be computer-analyzed and evaluated invarious ways.
Image analysis on PC

Research and Development

49

Fig. 1: Image recording systems.
Fig. 2: Backlighting method.
Fig. 3: Laser intersection method.
2

Backlighting method
In this case the headbox jet is illuminat-

Cameraed from below and photographed fromabove. The result is individual or series

Macroturbulence image analysis

shots of the jet surface which are suitable both for qualitative and quantitative
analysis.
This method can be used for example toCold light source

Headbox jet

analyze microturbulence on the jet surface, and with suitable image processing,Microturbulence image analysis

Jet photographlongitudinal structures can also be revealed and analyzed.

3

Laser intersection method

CameraHere the jet is intersected by laser beamLaser

to give a precise image of the surface
profile. This profile is recorded by highspeed camera, and the images are thenanalyzed.

Eachindividual

image

is

Mean deviation [mm]Averaged surface profile

Headbox jet

processed into metric data readings,

Jet width [mm]which are evaluated statistically.
Image processing

Wavelength analysis
Var. coeff. integral [%]Original image

RMS amplitude

Jet irregularities, for example, can be
identified with high precision by averaging out the 2000 images per second andcarrying out frequency/wavelength analysis. In many cases this also allows their
origin to be determined.

By comparison:jet photograph

Wavelength [mm]50

C O R P O R AT E N e w s

51“Impact Systems, Welcome Aboard!”
Impact Systems joins Voith Sulzer Paper

By combining papermaking and control

Technology: bringing papermakers atechnologies, we can substantially en-

new level of manufacturing capability.

hance the performance of many of our
new developments and improve the

On January 21, 1998 Voith Sulzer Paper

results for our customers.”

Technology acquired Impact Systems,
Inc., and raised the potential perfor-

Kenneth P. Ostrow, President and CEO ofmance of papermakers worldwide. The

Impact Systems, adds “I am exciteduniquepapermaking,about our new opportunities to bring pa-

measurement and machine actuator ex-

permakers a higher level of manufactur-perience offered by this new team willing capability. We will start by combin-

provide paper mills with quality, efficien-ing our existing products with those ofcy and customer service opportunities

VSPT to provide the broadest range of

not previously available.

paper machine control solutions. For the

combinationoffuture, we are working together on inno-

The authors:
Janine Nagel, Impact Systems,
Germany;
Barclay Wallace,
Impact Systems, USA

Impact pioneered electric infrared (IR)vative new products shaped by Voith

moisture profiling, and is a leading sup-Sulzer’s deep knowledge of papermaking

plier of profile control actuators. Theseand Impact’s leading expertise in on-line

are all part of Impact’s complete family

quality sensors and paper machine pro-of on-line paper Quality Control Systems

filing actuators. We are going to show

(QCS). Impact’s innovations fit hand-

paper mills some amazing opportunities

in-glove with VSPT’s great strengths in

to improve product quality, manufactur-

the papermaking processes and machin-ing efficiency, and customer service.”ery. The result is a combination of technology, industry knowhow, expertise and

The team got its start at consolidated

resources

bringing

The potential of the Voith Sulzer Paper

new and exciting offerings to the paper-

Technology/Impact team became clear

makers.

when together we achieved great results

that

are

alreadyon PM 35 at Consolidated Papers’ mill

1

In the words of Hans Müller, President

in Stevens Point, Wisconsin. This new,and CEO of Voith Sulzer Paper Techno-

high-speed Voith Sulzer specialty ma-logy, “With the acquisition of Impactchine includes the ModuleJet headbox

Systems, we are significantly enhancing

with advanced CD weight control using

our technology offering. Many of our

Impact’s fast, high-precision weight sen-future developments of sophisticatedsor. Five Impact Advantage Plus scan-

paper machinery require the full integra-

ners with 11 paper quality sensors sup-tion of advanced sensors, actuators andport the latest in supervisory control,

controls to achieve their full potential.

while their ThermaJet CD caliper and52
Fig. 1: Impact Systems is located in Los Gatos,
California – the heart of Silicon Valley.
Fig. 2: Impact scanner with sensors on
Consolidated Papers machine.
Fig. 3 and 4: ModuleJet headbox.
Fig. 5: Spectrum IR Gas system.
Fig. 6: Millennium System in Crown Vantage,
Parchment, Michigan Yankee 1.
Fig. 7: InfraPac Electric.
Fig. 8: ThermaJet.
2

3

InfraPac electric IR moisture actuators
yield

superior

caliperandmoisture

profile control. The smooth integrationof the ModuleJet, DCS (Distributed Con-

4

I The InfraPac moisture profilingsystem – achieved amazingly good CD
moisture control.
IThe direct Ethernet communications

include:I An ultra-stable scanner and high-precision weight sensor tripling the profile measurement precision of other

trol System), and the Impact products

from the Impact scanners to the mill’sgauges. Of course, this yields better

was largely attributed to Impact’s “totally-

DCS and to the VSPT Profilmatic CD

profiles. In the words of Rudolf

open”,

weight controller allowed easy, fast

Münch, Manager of Process Controls

Ethernet and TCP/IP (network protocol)

access to sensor information for oper-for Voith Sulzer Paper Technology,

communications directly from the scan-

ator interface and control.

“The Impact unfiltered basis weight

distributed

sub-systems

plus

ners and actuators. Wolfgang Griech,

This successful effort demonstrated the

profile has better precision than theManager Development Controls for Voith

exciting potential created by the two or-filtered basis weight profiles from oth-Sulzer Paper Technology, “In working

ganizations.

er QCS systems. High precision profiles are required to achieve the fullwith various QCS (Quality Control Sys-

performance potential of ModuleJet.”tem) suppliers, we found the Impact sys-

The Millennium family from Impact

tem far more open, which allowed us to

Impact’s recently-introduced Millennium

easily access the information we needfamily surely competes for “best of

I The broadest family of proven profil-for optimum results.”

breed” in papermaking measurement,

ing actuators and advanced CD con-control

information-management.

trols in the industry. The gas and elec-

Although many system elements con-Millennium introduces a new generation

tric IR profiling/drying systems are es-

tributed to the results at Consolidatedof open system architecture that willpecially noteworthy in their ability toPapers, the three most notable were assupport development and growth welladdress moisture streaks and drying

follows:

into the next century. Millennium isproblems, and boost productivity.

I The combination of the ModuleJetalready proven, with eleven systems

headbox and Impact’s weight sensor –yielded excellent basis weight profiles.

andinstalled. Customer-reported highlights

I Distributed “totally open” sub-systems, using Ethernet TCP/IP, and oth-

53

5
6

DynaStep

Steambox

Spectrum Gas

AdvantagePlus
SSIR Scanner

InfraPac

AdvantagePlus
SSIR Scanner

ThermaJet

7

er open standards, offer open connec-

AdvantagePlus
Scannercompanies.

tivity to other control and information

I InfoPac Paper Machine Information

systems. This design removes the

System continuously monitors andconnectivity roadblocks presented instores the real-time paper machineother allegedly “open” systems.

data, allowing mill personnel to recall
it on-demand, to improve quality, effi-

IFull

8

maximizes

ciency and customer service. InfoPac

reliable operation in the harsh paper

uses standard Microsoft programs andmachineaddition,an ODBC (Open DataBase Connectiv-

Millennium is designed with advancedity) compliant database, for user-

diagnostics, remote support, and In-

friendlyternet troubleshooting aids, to allow

This product, under development at

mills to assume any degree of mainte-

Impact for over one and a half years,

nance responsibility.

has already assisted the Voith Sulzer

systemrobustness

environment.

In

Windows-based

operation.

Paper Technology automation group in
Millennium also offers some new and in-optimizing applications.

novative technologies, including:
I Ethernet/DDS (Data Distribution System)

communications

networking,Millennium boosts productivity
at Crown Vantage

which delivers a highly efficient and

The Millennium family has been in devel-reliable control network and allows

opment for over two and a half years,

easy future expansion. Voith Sulzer

and was first offered to Crown Vantage.

Paper Technology and Impact jointly

Robert Olah, President of Crown Van-developed this technology, for use intage, notes: “Back in early 1996 Impact

the future control systems of both

approached us with a whole new system

54

Fig. 9: Reel Browser Graphics.

9

concept. Our mill in Port Huron, Michi-

I A full family of Actuator Systems,

gan was the very first to install the

including DynaStep Weight Profiling,

The team of Voith Sulzer Paper Technol-

Millennium offerings, which went on two

InfraPac Electric IR Moisture Profiling/

ogy and Impact Systems will lead themachines, Impact’s uniques gas andDrying, Spectrum IR Gas Drying,way in developing and installing theseelectric IR systems solved a chronic

SteamPac Moisture Profiling/Drying,new integrated machine and control

moisture problem on our Yankee, andand ThermaJet Caliper Profiling.

technologies, and set new standards inpaper mill quality, productivity and cus-

gave us an 8 percent speed increase.”
I InfoPac Paper Machine Information
The latest Millennium installation is on

System with Reel Quality Browser and

the PM 1 specialty machine at the Crown

productivity tools.

tomer service in the future.

Last but not least:

Vantage Parchment, Michigan mill. “We
needed to achieve a quantum leap inThis system, as installed, should reduce

Impact Systems GmbH is pleased toqualityKarl

the MD and CD quality variations by upannounce the latest Millenium System

Christianson, V.P. Operations, Specialty

to 50 percent and increase machineorder which was finalized just before

Papers. “When we evaluated suppliers,

speed by over 15 percent.

press-time. Papierfabrik Scheufelen in

andproductivity,”

says

Oberlenningen, Germany recently or-

Impact came to us with an innovative
solution, including gas and electric IR

New paper machinery with integrated

dered a Voith Sulzer ModuleJet Headbox

systems, which was not available fromcontrols

with ProfilMatic CD control in a quality

other QCS suppliers. The InfoPac Infor-

Traditionally, major advancements in pa-

improvement project for their PM 6.

mation System will provide us with de-per machine control have come from thetailed graphic information concerning allprocess control companies. Today, that

In order to optimize the performance ofaspects of roll quality. Our technical andparadigm is shifting in favor of the new

this investment, Scheufelen selected thecustomer service department see this as“Machine and Control” suppliers that

Millenium QCS from Impact Systems toa highly valuable tool when working withhave both the machinery and controls

replace the existing measurement sys-

our customers.”

experience. “The ultimate performancetem. An additional important factor inof future papermaking equipment will

Scheufelen’s decision was the under-

Highlights of the Millennium on Crown

strongly depend on having the rightstanding that with Impact Systems now a

Vantage PM 1 include:

sensors, actuators and controls,” says

member of the Voith Sulzer Paper Tech-

I AdvantagePlus Measurement System

Hans Müller. “Thus we believe that the

nology team, leading-edge paper ma-

with three scanners supporting six

key for paper industry future advance-chine and automation technology canquality sensors.

ments will come from combining paper-

now be provided in a comprehensive,

making and control expertise.”integrated package.

55

Corporate News:

Mexican seminar a huge success
The Stock Preparation Division of Voith
Sulzer Paper Technology North America
Inc., in conjunction with our Mexican
agent, Macorvi S.A. DE C.V., recognized
the importance and value of its Mexican
customers by conducting two back-toback seminars on October 13th and 15th,
1998.
The author:
Jeffrey Spielbauer,
Stock Preparation Division
North America

The seminars, held in Mexico City andMonterrey, reached attendance levels
beyond expectations with nearly 150
customers participating in the two presentations. The success can also bemeasured by the fact many senior management personnel attended, including
mill managers and general directors.
Mario Cordoba, owner of Macorvi, opened
each of the seminars with warm greetings to the participants. Presentations on
Pulping, Screening, Flotation Deinking,Water Treatment & Rejects Handling
Bleaching and Systems Technology as
well as Mill Reviews and an After Market
update followed.

Mario Cordoba, Macorvi S.A. DE. C.V.,
holding his welcome address.

Presenters included Dave Westenberger,
V.P. Sales & Marketing; Jeff Spielbauer,
V.P. Applied Technology; Jerome Herro,Manager Deinking Technology; Frank
Meltzer, Manager Unbleached Fiber Systems; Michael von Grumbkow, General
Manager, Meri Papertec, Inc. and Patrice
Barbeau, Sales Manager After Market. All
presentations were greeted with atten-

tiveness and lively question and answer
discussions.
The Mexican market has long been asupporter of Voith Sulzer Paper Technology’s equipment and system technology.
With the help and support of Macorvi
Voith Sulzer Paper Technology has
secured orders for 10 of the 13 Deink
Plants installed in the Mexican market
and has equipment installed in 60 of the
66 mills present in Mexico. State-of-theart technology is incorporated in many ofthese installations as can be seen by arecent order incorporating Voith Sulzer
Paper Technology and Meri Papertec,
Inc. equipment in a zero effluent discharge board mill.
Considering the attendance level, as wellas positive feedback following the presentations, there is no doubt Voith
Sulzer Paper Technology is considered
the major Stock Preparation Equipment
supplier in Mexico.
Mexico, with a population of 92 million
people and the economic spark of the
NAFTA agreement, is emerging as a substantial recycled paper product market.
Voith Sulzer Paper Technology North
America Inc. is poised to assist our valuable Mexican customers with productand systems technology as well as aftermarket service as they move forward to
the next millennium.

56

New Offices and Service Centers Representative
Competent local support and service

China

trained team at the Beijing office. China’s

within easy reach of all our customers.

China’s capital is changing its face.

paper industry is currently expanding

This important aspect of our image –World-famous monuments to the illustri-rapidly to meet the country’s enormousand our market success – is now being

ous past (see above) are being joined bydemand for paper and board – 33.5 mil-systematically expanded.

more and more skyscrapers as the econ-lion tonnes in 1997, of which 6.5 million

omy expands into the third millennium.

tonnes were still imported. This already

One of these modern office buildings

makes China the world’s second largest(foreground of picture below) is the home

paper consumer after the USA, and con-of Voith Sulzer Papiertechnik Beijing

sumption is expected to double within theCentral Representative Office, founded on

next decade. The Chinese paper andOctober 1, 1998. This replaces the China

board industry is meeting this demand

office of J. M. Voith AG, Austria, dating

withback to 1994. Under the newly appointed

through rebuilds and new installations.

managers Ming Ming Liu and Frank Ople-

Voith Sulzer Paper Technology’s repre-

tal, our Chinese customers are looked

sentative office here can therefore lookafter by a highly experienced and well-forward to a full workload in future.

greater

production

efficiency

57

SwedenSummer 1998 marked the acquisition ofLessebo Valssliperi AB, one of Scandinavia’s leading roll trimming specialists.
Founded decades ago, this company has
a highly experienced team of specialists
with first class equipment – including theUSAworld’s largest trimming machine for

On October 6, 1998 Voith Sulzer Paperrolls up to 14 m long and 2.5 m diameter.

Technology opened a new service centerin Farmington, New Hampshire.

Services here range from roll trimmingand super-finishing to dynamic balanc-

This modern building complex includes

ing. Activities will be expanded in future

about 3500 m 2 of shop floors and offices.

to include on-site servicing and own

The entire range of services will be pro-spare

vided here, initially by a highly trained

Reinhard Müller, head of our European

team of twenty. All the special machines

Service Division, sums up as follows:

required for roll trimming, renewal and“We now have an excellent base inbalancing are available at this center, inLessebo for serving not only customers

which more than 7 million USA dollars
have been invested.
The new Farmington service center will

manufacturing

facilities.

in Sweden. In future, the whole of ScanChris Turner (left) and Ray Hall (right)
talking with Jeanne Shaheen, Governor of
New Hampshire.

provide competent local support for thepaper and pulp industries in the northeast USA and eastern Canada.

partster, pointed out how well cooperation had
already started with the local paper andA public “open day” was held to celebrate

pulp industry. If demand continued tothe inauguration of this service center,rise in this way, plans for plant expansion

the latest of nineteen.

and doubling up the team would soon be
put into practice.

Guests of honour included Jeanne Shaheen, Governor of New Hampshire. She

Great attention has been paid at thispaid tribute in her address to Voith Sulzer

new center to exemplary environmental

Papier Technology’s commitment to job

compatibility. Clean and efficient energy

security and creation in this region. Chris

utilization is just as much a part of thisTurner, manager of the new service cen-concept as loopwater recycling.

dinavia will benefit from the local service
and support for which Voith Sulzer Paper
Technology is so renowned”.

58

Paper Machinery Division Graphic:
International Customer Conference
March 24 - 26, 1999

“Process & Progress”, integrated process concepts and progressive solutions.
It is under this central theme that we would like to provide you with detailed information –on your future and ours in the paper world.
Some of the papers

What will the future bring? How will themarket of tomorrow for graphic papers
look? What requirements will dominate inMarket developments and future de-paper production, and how has Voith

mands on graphic papers – Voith Sulzer

Sulzer Paper Technology geared itself toPaper Technology - fit for the future –this? What will ensure a competitive lead

Concepts for significant progress inandpaper technology – Greater productivity -animproved

returnofcapitalonline? – Visions for paper making –employed?
Replies to these important questions will

Heidenheim: Hellenstein castle

Success through partnership.

be given in an international conference

market research will present development

If you would like to attend this sympo-

hold in Ulm and Heidenheim, Germany,

trends. A visit to our Research and Devel-sium but have not yet received an invita-

from March 24 – 26, 1999. Experts fromopment Facility, combined with a look attion, please fax your name and address

Voith Sulzer Paper Technology and guest

future-oriented paper machines in ourto the editor, twogether on

speakers from the industry and fromassembly shops, will round off the event.

(++49) 73 61 94 98 94.

Historic Ulm with cathedralP a p e r C U LT U R E

59A monument to Swiss industry:

Bischofszell Paper Machine Museum
Although 223 tonnes of steel thirty sevenpaper technology enthusiasts decided tore-inauguration on August 28, 1998 – themetres long are impressive enough,preserve this last surviving oldtimer of150th anniversary of the Swiss Federal

paper machine 1 in Bischofszell is rather

the European paper industry.

Constitution. Since then Bischofszell Paper

modest by today’s standards. When built

Machine Museum has become one of thein 1928, however, it was state-of-the-art

Led by Werner Seebass, they founded

most popular monuments to Switzerland’sin advanced papermaking technology.

the Bischofszell Association for Histori-

industrial heritage.

Until 1991 this Voith machine No. 353

cal Paper Machinery, and invested more

operated day and night almost nonstop.

than 25,000 man-hours in restoring the

The little town of Bischofszell, on the river

Over more than six decades it produced

machine to its former glory.

Thur not far south of Lake Constance, iscountless tonnes of writing/printing andprotected today as part of Switzerland’s his-packaging papers. But in the end old age

Thanks to their vast experience and un-

tory. Mills and factories were set up herecaught up, the rust started to collect, andbounded enthusiasm, this fully functional

along the banks of the Thur right from thedemolition loomed – until a group of

historical machine was ready for official

beginning of the industrial revolution.

60

Werner Seebass (left) founder of the Bischofszell
Association for Historical Paper Machinery,talking with Wolfgang Möhle, Corporate
Marketing Voith Sulzer. Behind them can be seensome of the carefully preserved historical records
on show in the Bischofszell Paper Machine
Museum.

The Bischofszell “Papieri”. Inside the hall in
middle foreground is the Voith fourdrinier paper
machine dating back to 1928.

Bischofszell’s “Papieri” was originally awent into service at the end of 1928, wasWhat is the spirit behind this restora-

weaving mill. The building complex in-designed for an output of 10 tonnes/day

tion? It is more generally recognized

cludes some interesting historical ma-

with a web width of 2200 mm. This

these days that not only the fine arts arechinery, including water and steam tur-machine No. 353 was very sturdy andworthy of preservation for posterity, butbines and a Diesel engine with generator

mature even by today’s standards, fully

also utilitarian things such as cars, aero-supplied by Sulzer Winterthur.

in keeping with the high standard ofplanes – and production machinery in all

Voith paper machine technology.

its many forms. And the beauty of machinery is well demonstrated in Bischofs-

Around 1887, weaving operations were
replaced by carton production. Later on

Thanks to its solid construction, the suc-zell: by the perfection of each individual

papermaking commenced here, and in

cessful restoration of this machine wascomponent, and the fascinating harmony

1927 a fourdrinier machine was orderedstill possible in 1991 after more than fiveof cylinders, rollers and gears in motion

from Voith Heidenheim. “PM 1”, which

years of standstill and slow decay.

– all driven by a single electric motor via

Paper Culture

61

innumerable belts and pulleys. In fact

fathers – whose principals were mosting” in ergonomic industrial architecture

one cannot help thinking here of Charleycertainly not dictated by profit alone.

which started to replace the old factories
in the twenties.

Chaplin in “Modern Times” – produced in1938 when the machine was already ten

Parallels can be seen in the Bischofszell

years old.

paper machine hall to epoch-making
trends in industrial architecture. For ex-

So Bischofszell is well worth a visit, par-Standing inside its own specially built

ample the AEG Berlin turbine hall, built

ticularly for those of us who not only

hall, the overall impression made by thisby Peter Behrens about twenty years ear-look to the future of our trade, but also

historical paper machine together withlier. With its advanced structural design,

relish the craftsmanship of the past. And

architecture and interior fittings is re-unimpeded width and generously dimen-

it is thanks to the Bischofszell Associa-

markable. It gives us some idea of thesioned window fronts, this is likewise antion for Historical Paper Machinery thatpride and determination of our fore-

outstanding example of the “new think-

this is possible.

Published by:Voith Sulzer Papiertechnik GmbH & Co. KG
Editor:Dr. Wolfgang Möhle, Corporate Marketing,
Voith Sulzer Papiertechnik GmbH & Co. KG,
Tel. (++49) 73 21 37 64 05
Fax (++49) 73 21 37 70 08
P.O. Box 1970, D-89509 Heidenheim
http://www.voithsulzer.com
Editorial coordinator:
Manfred Schindler, D-73434 Aalen

Paper Technology Journal

Newsmagazine for theinternational clientele,
partners and friends of

Design, layout and typesetting:
MSW, P.O. Box 1243, D-73402 Aalen
Copyright 2/99:
No part of this publication may be reproduced
or copied by any means whatsoever without
the express permission of the editor.

2/99/20 SDZ. Printed on chlorine-free bleached paper manufactured with Voith Sulzer Paper Technology machinery.

“twogether” is published twice annuallyin German and English. Contributions by
independent authors do not necessarilyreflect the opinion of the publisher.
Please address all correspondence andinquiries to the editor.