twogether
Paper Technology Journal

26

Water for life requires inventiveness I Daio Paper Mishima– from a single source I Saving with Voith Paper products

2

Contents

4	Water for life requires inventiveness.

10 D
 aio Paper Mishima PM-N10– from a single source.

74 New Chief Executive Officer ofVoith AG, Dr. Hubert Lienhard.

ReportProducts

Service

4 Water for life requires

22 New steam technology concept

56 With pre-engineering to theinventiveness72 Premium paper with ahandcrafted look

improves drying process

26 Up to 25% energy savings with
IntensaPulper

28 Field instruments added to
product portfolio

New Plants

31 LunaFilm and SolarCoat roll covers

10 Daio Paper Mishima PM-N10

34 Energy savings up to 30%

for successful film coating– from a single source

12 One Platform Concept meets
customers' wishes

Rebuilds

36	WebTense – replacement oflower costs

R&D
66 OnV FlocSpotter measures formation

conventional spreader rolls

already on the forming wire

38 PrintForm HS – forming fabric for

68 SafeTailing – reliable transfer

high-speed former

42	PrintForm HR – forming a quality

18 German newsprint PM becomes

45 Cell Platform – clothing for

SC-B paper machine in China

pulp drying machines

20 Modernization of two deinking lines

48 Nipco roll in successful use
50	Prevo – the new threading
process technology

53 Atmos: fresh wind for tissue paper2

program62	RollCare, RollRep and RollUp Solutions

due to TerraGloss

sheet on a robust fabricat Steinbeis Temming Papier

Perfect Fit mill

58 EduCAT – new computer training

even safer

70 AirEx AT-V – optimizes coating color
air removal

News
74	Change at the top of Voith AG
75 News from the Voith Group

26 I 2008 I Voith Paper I twogether

EDITORIAL

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

Dear customers and readers,more cost-efficiency thanks to Voith
Paper's One Platform Concept.

“Water for life requires inventiveness“– that's how we headed our title

But our core business includes more

report. At the same time, it is the third

than just new systems. The success-report in a series in which we concern

ful restart of the earlier Maxau PM 6

ourselves with the raw material

in Dongying, China (pages 18-19), or

problem in our industry. Voith Paper

the modernization of two recovered

has clearly made it a goal to develop

paper preparation systems in Glück-

technologies, products and systems

stadt, Germany, are importantthat effectively reduce water, energy

projects for Voith Paper.

and fiber consumption in paper
production.

The topic of saving energy runs like a
red thread through this edition of

In the report, this is impressively

twogether. With the Value+ concept

demonstrated with the example ofin the drying process, the IntensaPul-

our new company, Voith Paper Envi-per for recovered paper dissolutions

ronmental Solutions (pages 4-9).

or the TerraGloss thermo-roll coating,

But also the maturity phase of ourhigh energy savings are possible.

Atmos process will draw attention to
the steps we are taking towards

I would like to recommend our cultu-

sustainability in the paper industry.

ral report on the Gmund handmade

With Atmos, we can produce high-paper mill (pages 72-73) to all friends

quality premium products for the tis-of traditional paper production.

sue market in a more environmentally

Gmund Paper opened an exceptional

friendly and cost-effective manner.

paper shop In Munich - a pleasure to
go shopping there.

We report on the commissioning of
the Mishima PM-N 10 at Daio Paper

Get in on the latest technologies andin Japan on pages 10-11. A complete-developments from Voith Paper.

ly new production line from a single

Have fun while reading!

source has come into being there.
You can read on pages 12-17 about
how you can produce the highest
quality papers with considerably

26 I 2008 I Voith Paper I twogether

On behalf of the Voith Paper team3

Report		 Water for life requires …

Report… inventivenessReportThe blue planet must remain in balance.

Darkness surrounds the astronauts in space andthen a fascinating blue planet appears before
them: Earth. Described by Apollo 14 astronaut
Edgar Mitchell as a sparkling blue and white jewel,
almost two thirds (71%) of the surface of thisplanet is covered in water. It sounds paradoxicalthat for the people living there, however,water is an extremely scarce resource. In fact,
only aboud 1% is available as vital drinking water.

6

26 I 2008 I Voith Paper I twogether
25

Report

Most of it is salt water or water that is

The Intergovernmental Panel on Cli-

attached to the poles as glacial ice.

mate Change fears that this number

Sustainable use of this precious

will increase to three billion by 2025.

resource is all the more important.

And this is not because there will be

Water-intensive industries such as theless water but because the per-capita

paper industry, are already making en-

consumption is continually rising andormous progress in this respect. The

more and more people have to shareinternational decade for action “Water

the fresh water supplies.

for Life”, proclaimed by the United Nations, began in 2005. Therefore, when

The example of New York illustrates

it comes to conservation of resources,

what impact several small measures

topics such as water scarcity, waste-

towards more efficient and, therefore,water treatment or sustainable water

sustainable use of the valuable re-use will be the focus of global interest

source water can have. In 1990, theretime and again up until the year 2015.

was a water shortage in the megacity,

In addition, “Water for Life” should

which forced the entire city to savepromote sustainable forms of water

water. The present balance proves

use and reduce by half the number ofthat a great deal can be achieved inpeople without access to safe drinking

private households. Measures inclu-

water.

ding flushing the toilet with lessquantity, repairing pipes or flow re-

Water shortage is getting worse

strictors for fittings resulted in eachresident using 100 liters less water

Today, half a billion people in 31 coun-per day than in the previous ten

tries around the world already suffer

years. The paper sector in particularfrom a lack of water. They have too

proves that industry also sees its

little clean drinking water at their

responsibility and takes it seriously.

disposal or none at all. Water could

For years, they have been working on

become even scarcer in the future.

doing justice to the resource water by

The paper industry can reduce whitewater loops and save water.

In 1990, there was a water shortagein New York that forced the entire
city to conserve water on a longterm basis.

26 I 2008 I Voith Paper I twogether
25

7Reportdeveloping new process technologies and continually reducing consumption.
Less water per kilo of paper
Two figures illustrate what theefforts in the paper sector havealready achieved. Back in 1974,
46 liters of fresh water was used to
produce one kilogram of paper inEurope. Today, while the average
consumption is just ten liters.
In the same period, the waterrequirement for pulp production
fell by 75%. Voith Paper Environmental Solutions (VPES) is working
on a paper production that uses
even less freshwater and produceseven less wastewater. The Voith
Paper group of enterprises, whichis still in its early years, has founda solution for reducing the specificwater consumption per kilogram of

Water consumption per kilogram of paper in liters

paper even further:

The Voith R2S Reactor at SCA Packaging in Lucca, Italy, takes care of the anaerobic
treatment of all the factory’s water. This produces biogas corresponding to the heatconsumption of more than 1,700 German households per year.

50

40

30

Wastewater goes back to where

If you consider that approximately

it came from

8,000 paper mills produce around

20

10

0
1974

Today

Water consumption on average for the
production of 1 kg of paper in Europe.

8by recirculating recycled wastewater.

383 million tons of paper, board and

The innovative R2S Anaerobic Reactor

cardboard worldwide, you get a clear

technology combined with the Limepicture of the scale of sustainable

Trap opens up new possibilities. It

production in this sector. What lies

makes the lime problem manageable

behind the solution by VPES is aand therefore opens up new possibili-

system technology that enables

ties for closing the white water

sustainable use of the precious re-

circuit further. It enables biologicallysource, water.

treated and decarbonized water to be

26 I 2008 I Voith Paper I twogether

REPORT

recirculated into the production pro-is downstream from the anaerobic

about the current situation of water

cess. It is precisely this kind of water

treatment step, is reduced.

reserves. “Water, a shared responsi-

recycling that ensures the averagewater consumption can be reduced

bility” is the name of the latest report,“Water, a shared responsibility”

further. VPES has therefore succee-

which leaves no doubt that proactive
technologies to counter further water

ded in coming a step closer to the

The VPES example makes it clear

shortages must be implemented“zero liquid effluent mill” it has beenthat Voith Paper is supporting thethroughout the world. And this means

striving for since the 1990s.

paper industry’s commitment to deal

beyond the “Water for life” decadewith the resource water in a sustaina-

too.

In the R2S Anaerobic Reactor theble manner with its new integrated

suspended organic load in the waste-water treatment concept.

water is converted into biogas with

These kinds of technologies are
essential to ensure the blue planet,a high calorific value by a digestion

The classic view of wastewater

the view of which leaves not only

process.

treatment as the “end of pipe” isastronauts spellbound, remains inundergoing a radical change.

balance and that paper will beThis degrades around 80% of the

Recycling wastewater moves thisable to be produced in greater

COD load (chemical oxygen demand).

last stage in water clarification closer

harmony with nature in the future.

The biogas that is created can beto the production process and there-

used to generate e.g. “green energy”

fore requires a comprehensivein the mill in a combined heat andprocess control system. The “Worldpower station. This goes in line with

Water Development Report”, which

the costs for sludge treatment andis published every three years sincedisposal. Furthermore, energy con-2003 under the guidance ofsumption for the aerobic stage, which

UNESCO, provides information

The Lime Trap at Leipa paper mill in Schwedt, Germany, daily removes about 3 tons of lime from the wastewater.

26 I 2008 I Voith Paper I twogether

9NEW PLANTS

The new paper production line at Daio Paper in Japan.

Mishima PM-N10 at Daio Paper in Japan

New paper machine from a single source
Daio Paper Corporation started in the summer last year the new production line Mishima PM-N10 in
Shikoku Chuo City in the Ehime Prefecture on Shikoku Island. This order was the first installation of acomplete new paper production line out of one hand in Japan.
Daio Paper’s PM-N10 “on-machine-

Paper and Voith IHI Paper Technology.

the C3-OMC and Super Calender.

coater” is a high-speed machine

The Mishima PM-N10 will be run

That means the labor costs at fullwith online coating and online calen-with a crew of only 9 persons compa-

production will be reduced by 50%.

dering for lightweight coated papers.

red to a coated paper production

The PM 8 producing 730 tons/day

All production aspects incorporateline with a crew of 16 people forcompared to PM-N10 producing

leading-edge technology from Voith

example on Daio Paper PM 8 with

800 tons/day.

Wire Section
DuoCleaner DuoFormer TQv

Tandem NipcoFlex Press
with transfer belt

Headbox
MasterJet II with EdgeModule

ProRelease

SpeedSizer AT
for Surface Sizing

Dryer section
TopDuoRun

45 dryer cylinders with
DuoStabilizers

Layout Mishima PM-N10.

1026 I 2008 I Voith Paper I twogether

NEW PLANTS

Project milestones

Daio Paper• Ground breaking ceremony –Daio Paper produces the full range

The official ground-breakingof papers, from newsprint, coatedceremony was in June 2006.

papers, tissue papers to paperboard• Building – The building was closed

Customer Comment
Akira Nomura
General Manager Papermaking
Department

as well as paper-processed products

and ready for the start of installationsuch as corrugated cardboard and“Our N10 machine can be utilized inof the sole plates for the paper

sanitary products, is active in thetwo ways, as film- and as blade coated,machine in January 2007

timber and forestry industries and has

this unique on-machine-coater is also

• End of mechanical installation with

its own fleet for the shipment of theirequipped with an on-line Janus calen-

start of commissioning commenced

raw materials and goods from and toder. Through trials at the Voith pilot

beginning of June 2007

the different locations worldwide.

machine, intensive discussions with

• Start Up – The first roll of paper was

us regarding the machine layout andproduced on August 5, 2007 at a

The company owns three paper mills

considering all technical details in thestart up speed of 1,452 m/min with

with an annual capacity of approx.

specification, this machine reached aa basis weight of 58 g/m².

3.2 Mio. tons of paper with approx.

high level of perfection and is now

2,700 employees and operates today

running in stable operation.

Delivery, installation and start up of

more than 40 subsidiary companies.

this new line was possible in record

Automation is highly advanced and istime because the responsibility for thesuperior in monitoring operation data,
quality data as well as in reproducibility.

whole paper machine including the reelContact

and the main interfaces came out of

The product quality obtained high eva-

one hand. The peripheral machine

Ryozo Shimizu
Voith IHI Paper Technology
ryozo.shimizu@voithihi.com

items installed by Daio Paper were also
monitored through Voith Paper.

luations from our end users especiallyregarding stiffness and printability. As it
was our expectation, we are very satisfied with N10 machine’s smooth opera-

Success factors in this project were theclose cooperation with Daio Paper,

Ewald Budweiser
Paper Machines Graphic
ewald.budweiser@voith.com

where the long lasting cooperation andrelation between the Voith Paper divisi-

tion.“ons and Voith IHI Paper Technology inJapan was a decisive advantage.

Pre-Calender
EcoCalender

After dryer
sectionSpeedSizer AT for
simultaneous Film Coating

JetFountain Coater

26 I 2008 I Voith Paper I twogether

After dryer
sectionJanus MK2
calender with 8 rolls

Reel
SiriusWinder
2 VariPlus

JetFountain Coater

11

NEW PLANTS

Up to three sizes for every paper grade

One Platform Concept meets customers' wishes
Since introduction of the One Platform Concept in 2001, Voith has delivered over 50 new paper
machines according to the One Platform Concept. In order to make the advantages of this innovative
concept available also for medium-size production facilities, three sizes were developed for all graphic
paper grades. Due to consistent optimization of machine widths and production speeds, economic,
highly modern and reliable production lines for all current customer needs can be offered.
Market requirementstion lines in order to satisfy the rapid-

to exist. In eastern Europe, new me-ly growing demand. In India and sou-dium-size lines that serve the regional

Today, the paper industry is exposed

theast Asia, projects with a capacity

market and can still be financed bymore than ever to the rising costs forof 200,000 tons per year dominate.

the respective investor will play an

raw material, energy and personnel in

The demand for smaller machines inimportant role. The dream of large

the face of stagnating returns for its

these regions has several reasons.

production lines in Russia will for thepaper products. In order to be able toOften, the supply of raw material ispresent remain just a dream, sinceinvest efficiently, the specific invest-

limited or the local market cannot ab-

the rising transport costs offset loca-

ment costs have to be in line with thesorb more paper. The financial re-tion advantages such as availability ofmarket. In addition, modern paper

sources in these regions often only

wood and low labor costs.

machines offer maximum efficiency

allow total investments of up to 200with minimal production costs.

million euros.

Customer requirements

Global trends

In Europe, investments are driven not

Regardless of whether a customer
from India requests a 200,000-tons-

ke of improvement of the paper pro-per-year line for newsprint, or adriver for new investments only in

duction lines profitability. Large newcustomer from China requests a

China, India and southeast Asia. Chi-

production lines with optimized pro-

600,000-tons-per-year line for copy

na will continue to have large produc-

duction costs will, therefore, continue

paper, the new One Platform Concept> 2,200

Design speed[m/min]

1,400
1,000
500
0

technologically more elaborate

2,000

Sizes
600
400
200
	Referencemachines

technically more elaborate
2,000

4,000
5,850 8,000
Wire width (mm)10,200 <12,000

Fig. 1: One Platform Concept – References since 2003.

12

Production capacity [tons/year]

by rising needs, but rather for the saToday, rising paper consumption is a

Sizes

1,000
800
600

Market demand
high
low

400
200
0

600
400
200

	Referencemachines
NP

MP

OP

FP

Fig. 2: One Platform Concept – Sizes.

26 I 2008 I Voith Paper I twogether

NEW PLANTS

offers the ideal solution for every• Newsprint = NP

Advantages of thecustomer's requirements.

• Magazine Paper (SC/LWC) = MP

One Platform Concept

That includes:• Office Paper = OP
• Fine Paper (wood-free coated) = FP

• Optimized production costs

By means of consistent standardization and optimization of the individual• Attractive investment costs

There are three sizes respectively:

modules, for each of the sizes Voith• Short delivery time

200, 400 and 600

is able to offer an economically opti-• Quick start-up curves• Consistent paper quality

mal concept that technologically
Using these categories, the machinemeets the highest market require-concept, the machine width and thements. Not only specific investment

design speed are determined. Of

costs, but also especially the operati-

course, the individual modules can beonal costs have been optimized for

For decades, Voith has built up andadapted to special customer wishes.

each of the sizes. Minimal consump-

expanded its knowledge and capabi-

The economical optimum is in eachtion of long fibers due to closed draw

lities in all areas of the paper produc-

case at the upper limit of a size. The

press sections, minimal steam con-tion chain.

nominal capacity of a production line

sumption due to high dry contents,

Voith Paper know-how

is also determined by the basis weight

low chemical costs due to optimized

Beginning with the paper machine,

to be produced. Depending on basis

process control and minimal watercompetence was extended to allweight (42, 45 or 48.8 g/m²) and overall

consumption due to shortening theprocess-influencing sections: auto-

efficiency, a NP 400 can thus produce

circulation loops are examples ofmation, fabrics, roll covers, ventilation

between 370,000 and 430,000 tons per

economic advantages for the paper-

systems, chemicals, water treatment

year. Experience shows that for somemakers.

and energy generation from waste.

paper grades not all three sizes are in

Added to this is the extensive expe-

The One Platform Concept unites all

demand, but instead initially two sizes

rience that Voith has acquired overthese competences as one solution.

are favored by the market (Fig. 2).

the last years with these lines. Thus,

One Platform Concept• NP 400 and NP 600

can be shortened. After a short time,

start-up and commissioning times• MP 400 and MP 600

the production lines are running at

For the four main graphic paper• OP 200 and OP 600

outstanding levels of efficiency andgrades:• FP 200 and FP 600

producing the nominal output.

Contact

Investment costs[Euros/ton per year]

Sizes

600
400
200

Anja Lehmann
Paper Machines Graphic
anja.lehmann@voith.com

Bernhard Kohl
Paper Machines Graphic
bernhard.kohl@voith.com
Machine widthFig. 3: One Platform Concept – Optimal investment costs for each size.

26 I 2008 I Voith Paper I twogether

13

NEW PLANTS

One Platform Concept – Examples
Thanks to the One Platform Concept, Voith Paper is in a position to offer the optimal paper machine forany desired paper grade.

Office paper: OP 200

DuoFormer D Single-NipcoFlex

MasterJet F

SpeedSizer

TopDuoRun

CombiDuoRun

MasterReel

In the growth regions of India, Thai-

MasterJet F with ModuleJet. The

Concept OP 200 not only in theland and Vietnam, there is a large

DuoFormer D allows optimal formati-mechanical engineering, but also

demand for high-quality printing andon and symmetrical sheet structure

especially in the automation. Starting

writing paper and also for copy pa-

over a large basis weight range.

with the process control system, theper. Predominantly short fibers from

Alternatively, a Single-NipcoFlex for

medium-size machine has all theplantations, but also from annuals

standard copy paper or a Tandem-

components for process stabilizationand even recovered paper are used

NipcoFlex for an expanded applica-that were developed for high-speed

as raw materials. Added to this aretion range guarantee optimal runnabi-

machines. A drive control developed

quality requirements for the finishedlity. Single-tier TopDuoRun pre-dryer

by Voith itself (Drive Command) gua-product such as are familiar fromsections with the most modern stabi-rantees quick optimization and stable

European standards.

lization technology provide for nearlyrunning. The data of the scanners arebreak-free operation. A SpeedSizer

directly linked with the respective ac-

As a rule, the basis weight range

allows application of starch and coa-tuators so that "misunderstandings"

extends from under 60 to overting for all applications. The after-

can be excluded.

100 g/m². Since either the raw mate-dryer section with differential heating

rial supply, the level of investment

secures the dimensional stability. The

In addition, the OP 200 has virtualor the regional market is limited, theon-machine calender creates thesensors that during grade changes

OP 200 offers the perfect machine

desired surface properties and canand start-ups allow the target para-concept.

be either a hardnip calender or Eco-meters to be reached and stabilized

Soft. Finally, the MasterReel produ-

quickly. Thus, efficiency rises andWith a wire width of 5.85 m and a de-ces large diameter parent rolls to be

more “quality tons on the reel“ aresign speed of 1,400 m/min, a size

processed further with a VariSprint

produced.

was determined that ideally meetswinder.

the market requirements. An approach flow system with low volume

But you recognize the particularfor quick grade changes feeds thesophistication in the One Platform

14

26 I 2008 I Voith Paper I twogether

NEW PLANTS

Newsprint: NP 400

DuoFormer TQv

Tandem-NipcoFlex

EcoSoft

MasterJet G

TopDuoRun		

SiriusMagazine paper: MP 400

DuoFormer TQv

Tandem-NipcoFlex

MasterJet

EcoSoft

TopDuoRun

Janus MK2		

SpeedSizer

SiriusFine paper: FP 200

DuoFormer D Tandem-NipcoFlex

MasterJet F/B

26 I 2008 I Voith Paper I twogether

SpeedSizer

TopDuoRun

EcoSoft

DynaCoat

CombiDuoRun

DynaCoat

MasterReel

15

NEW PLANTS

Interview about the
One Platform Concept
Kurt Brandauer
Executive Vice President
and Division Manager
Paper Machines Graphic
and Specialty Papers.

twogether:mum production results with consi-

width and speed. We are sure that weVoith first introduced the One Plat-

stently high product quality are what

can thus offer types of systems thatform Concept seven years ago. What

our customers value about the One

signify a maximum of efficiency forexperiences have you had since then

Platform Concept.

our customers.

twogether:

twogether:and what feedback have you received
from your customers?

Now you are going one step further

Standardization and innovation – isn't

Kurt Brandauer:

and offer standardized sizes for eachthat a contradiction?

Introduction of the One Platform

paper grade under the One Platform

Concept was a milestone for theConcept. What advantages does thisKurt Brandauer:

development of ultra-modern,standardization have for your custo-

No, quite the contrary. Throughefficient paper machines.

mers?

standardization of the production

The basic idea is simple: one platform

Kurt Brandauer:

research and development in a

for all graphic paper grades with use

We know that our customers are

considerably more targeted fashionof standardized modules (headbox,

confronted with rising costs for ener-

than previously. Experiences withpress, dryer section, etc.). Standardi-

gy and raw materials, without being

operation of the production lines flow

zation of the modules means that weable to raise the paper prices to thedirectly back into our development

can transfer operational experiencessame extent. The specific investment

departments where they are con-with running production lines to othercosts are therefore the decisive

stantly working to improve thelines and thus can ensure targeted

criterion for every investment. In or-

efficiency of our systems of the 200,

research and development.

der to lower them, we have to syste-

400 and 600 series. Innovations

matically go one step further withrequire a systematic approach sostandardization.

that they don't just go up in smoke.

lines, we can use our resources for

We get outstanding feedback fromour customers. After all, the use ofWith the One Platform Concept,

proven modules means an assurance

Not just the individual modules but

we have created the framework toof the investment success for thealso the sizes of the paper machines

put innovations on course in a targe-

project. Quick start-ups and maxi-

are being standardized with regard toted fashion for our customers.

16

26 I 2008 I Voith Paper I twogether

NEW PLANTS

twogether:

twogether:

Kurt Brandauer:

Let's take an example. With the size

Can you – at a customer's request –We have very consciously decided

200, Voith has standardized paper

nonetheless build a paper machine

against such a policy. With us, allmachines with a width of 5.85 m.

that deviates from the standards and,customers get a product line thatfor example, produces newsprint atmeets the highest quality standards.

Do you see a global trend towards

a width of 6 m and a speed of

The name Voith stands for outstan-smaller machines?

2,000 m/min?

ding quality and reliability of ourmachines. Regardless of whether a

Kurt Brandauer:

Kurt Brandauer:

customer purchases a newsprint

We see that the “bigger, wider, faster“Of course we can build machines

machine of the NP 200 or NP 600

trend doesn't meet the customers'that deviate from our standards.

size – the customer can expect theneeds in all markets. Precisely in

But we are of the opinion that with asame quality, both regarding our

India, southeast Asia and easternmachine of the size 200, 400 or 600,

machines and systems and also

Europe, the market calls for smaller

our customer gets the optimal machi-

regarding paper quality. We makemachines. First of all, the financial

ne regarding efficiency and minimal

no compromises with quality.

resources there are often limited, andinvestment costs. Solutions that

secondly, in some circumstances thedeviate are possible in principle, but

local market doesn't absorb moreas a rule more expensive.

than 200,000 tons per year.
twogether:
We have taken these basic conditions

In many industries one sees thatas a reason to develop the size 200.

along with the main product line,

We want to be able to offer every

suppliers maintain a low-perfor-

customer a machine that gives themance, cheap product line undercustomer a minimum of specificanother brand name.

investment costs – regardless ofwhether 200,000 or 600,000 tons

What is Voith's view of this productper year are required.

policy?

26 I 2008 I Voith Paper I twogether

17

REBUILDS

Successful restart of the earlier Maxau PM 6 in Dongying, China

German newsprint PM becomes
SC-B paper machine in China
Is a paper machine that has been dismantled to make way for a faster new machine no longer of use?
With a little innovative thinking, the answer is no! Here is the proof:

How it all started

could not mean “continue as before”,

What had to be done?

that is to produce newsprint paper.
In 2003, Stora Enso commissioned

Today, machines of this type are

What had to be done to make the oldVoith to convert the 8,100 mm wide

almost 11 m wide and operate at a

PM 6 “fit” for SC-B and newsprint was

PM 6 in their mill in Maxau, Germany.

speed of up to 2,200 m/min. Therefo-clear: On the engineering side, theThe term “conversion” is something of

re, reactivation of the PM would only

existing 2-roll soft calender had to be

an understatement. Looking at it more

be a good idea if high-quality pro-replaced by a modern multiroll calen-closely, it was the installation of an al-

ducts, for example SC-B offset paper,der. A Janus calender particularly

most completely new production line.

could be produced on it in future. Chi-lends itself to this. Its roll stack angled

The 35 year old PM with an annual

na appeared to have a longterm needat 45 degrees works especially wellcapacity of 140,000 tons was replaced

for such quality. However, taking intowith the sheet run.

by a state-of-the-art PM with an out-

account the production line efficiency,

put of 260,000 tons per year. The old

the PM should also be able to produce

But one particular challenge still had

PM 6 was dismantled and initiallyhigh quality newsprint. While Stora

to be overcome: Stora Enso and Hua-placed in interim storage. Thus, Stora

Enso and Huatai Paper considered a

tai Paper wanted a cost-optimized

Enso gained some time to consider

joint venture, Voith was to examine theconcept. Within the overall concept

other possible uses. It was clear fromconversion options and, if applicable,

and taking into account the quality

the beginning that “continued use”

develop a modernization offer.

and safety requirements, Voith thenexamined the degree to which it was

Opening ceremony of the PM 6 in Dongying, China.

possible to continue using the existing
equipment of the soft calender, to modify it and still meet the technologicalobjectives. After a thorough examination of the old PM and its parts, theresult was that both the deflection
compensating rolls, including their
hydraulics, and the thermo roll andtwo steam moisteners could be usedagain. Furthermore, Voith advised thatthe entire PM be equipped with acompletely new web transfer system.
Besides the machine components, theexisting automation was also put tothe test. The previous machine-orien-

18

26 I 2008 I Voith Paper I twogether

REBUILDS

ted controls should be replaced by thealso contributed to the success.

modern OnControl system. Particular

After the automation engineering wasattention had to be paid to ensure thefinished, the reconstruction of thereused hardware and the new, Siemens

modernized PM 6 began in May 2007.

PCS 7-based controls were optimallycoordinated. In addition, it was decided

Thanks to the good preparation, theto renew all pneumatic and hydraulicinstallation was trouble-free. The fact

control components and the field de-that the new Janus calender could bevices relevant to the machine controls

completely assembled in the Krefeld

as part of the rebuild. As a result of theworkshops in advance and all of its

modernization, it also made sense toessential functions tested made acreate entirely new documentation for

significant contribution to the smooththe machine-oriented controls, theinstallation. The OnControl controls

pneumatics, and the hydraulics. The

were similarly subjected to several

installation of an OnQ ModuleTherm

tests before delivery and adapted toactuator was recommended for reliable

meet customer requirements. Thus,

control of the CD caliper profile on thethe PM 6 was able to be started ahead

Janus calender – as usual, controlledof schedule on 25 November 2007 inby the Profilmatic software.

Dongying and was accepted by theoperators just two months later –The developed concept convinced thea result of the cooperation by thepartners Stora Enso and Huatai Paper,

Stora Enso and Voith teams.

Customer Comment
Carsten Wenk
Operational Director

so that Voith received approval for therealization.
How the job was done

Today, the PM 6 in Dongying is theStora Enso Huatai

first and only paper machine in China(Shandong)on which SC-B is produced on line.

Paper Co. Ltd.

And the establishment of this paperFirst, the paper machine had to bequality has also been successful, be-unpacked at the mill site in Huatai, thecause the production line is operating

components checked for completenessat 100% capacity with the production

and condition and, in some instances,of a high-quality SC-B product.

refitted. When stored in 2004, the PM

The “old lady” is once again gleaming

was maintained but not restored.

in her youthful splendor and the con-

A trouble-free installation within the

cept for the joint venture between

given tight timeframe would not have

Stora Enso and Huatai Paper has

been conceivable without fastidious

been a complete success. Thanks toinspection using decadesold documen-

their know-how and the competenttation and the specialist support ofand committed staff, Voith masteredvarious Voith construction engineers

this difficult assignment with flying

and technicians. Voith took on thecolors and was even able to exceed

basic engineering tasks, which madethe customer’s expectations.

a fundamental contribution to the pro-

The PM 6 is the fifth Voith PM to beblem-free and quick rebuild time.

successfully put into operation on

The close collaboration with Stora

Huatai premises within seven years –Enso Huatai and Haisum Engineering

a fantastic result.

26 I 2008 I Voith Paper I twogether“The early commissioning, undershooting of the project costs, customer
acceptance of the product and production clearly above the plan since commissioning make this project a success.
All those involved in the project haveaccomplished outstanding things andVoith clearly contributed to it.“Contact
Bernhard Häussler
Paper Machines Graphic
bernhard.haeussler@voith.com

19

REBUILDS

Modernization of two deinking lines in Glückstadt“DIP on demand” for faster grade changes
Voith Paper Fiber Systems has modernized and extended two
deinking lines (AP2 and AP3) at Steinbeis Temming Papier, Glückstadt, Germany. At the touch of a key, these rebuilt lines prepare
deinked pulp in various qualities for printing and copying papers.
The line concept developed for this purpose enables faster andmore frequent grade changes.

Voith Paper Fiber Systems has mo-

The line concept developed for thisdernized and extended two deinking

purpose enables faster and morelines (AP2 and AP3) at Steinbeis Tem-frequent grade changes. While line

ming Papier, Glückstadt, Germany. At

AP3 continuously produces deinked

the touch of a key, these rebuilt lines

pulp (DIP) at about 66 to 70% ISO

prepare deinked pulp in various quali-

brightness, line AP2 must produce

ties for printing and copying papers.

DIP at 60 to 90% ISO brightness

View of the DIP line in Glückstadt: screening, drainage and thickening.

20

26 I 2008 I Voith Paper I twogether

REBUILDS

Storage tower inflow
Disperger 2 inflow
Flotation
Disperger 1 inflow
Dumping chest

Technological data of DIP line AP2
DIP production:

460 tons/24 h

Yield (depending on grade):

81 - 75%

Brightness increase:> 20% ISO

Dirt speck reduction:> 98%

Stickies reduction (Tappi):> 98%

Specific energy consumption:

max. 565 kWh/tSpecific effluent:max. 8 l/kg

Screenshot shows brightness development over the subsystems of DIP line AP2during automated grade change.

with extremely fast grade changequirements. For the automated grade

requirements. In other words:

change program, in addition to con-

DIP on demand.

ventional sensorics, Voith uses for the
first time newly developed brightness

Based on the compact and energy-

sensors that also measure the UV

saving Voith EcoProcess, line AP2 iscomponent.

designed for furnishes with 20 to
35% ash content and 35 to 65 SR

Thanks to intelligent bleach control(118-365 CSF) freeness. All the line

(OnQ Bleach), brightness uniformity ismachinery and quality control sy-

improved nearly to perfection while atstems can be programmed to the tar-

the same time reducing bleachingget values of the various grades. Only

agent cost outlay.

Customer Comment
Michael Söffge

one qualified operator is required forthe entire line (not including recove-

President

Flying grade changes

Steinbeis Temming

red paper charging), thanks to automated operation with startup/shut-

To enable almost immediate grade

down sequences programmed intochanges, overall stock consistency is

the process control system.

continuously determined by a new

Papiermethod combining fiber and fillers
The recovered paper furnish for thesecontent measurement. Meanwhile,“Thanks to Voith as system supplier,

DIP lines originates both fromthere are several trouble free grade

we successfully realized the extremely

household newspapers/magazineschanges each week at Steinbeis

demanding modernization of our AP2

and from superior grade office waste

Temming Papier without any signifi-

deinked pulp line.”with high filler content. Fiber andcant outage time.
Contact

fines losses have been minimized bydispensing with washing, for the first

The new line concept has greatly sim-time in this application area.

plified office paper production logistics, thus eliminating the need and

A production control system adjusts

expense of keeping long-term inven-

the line throughput according to re-tory of each individual grade.

26 I 2008 I Voith Paper I twogether

Falk Albrecht
Fiber Systems
falk.albrecht@voith.com

21

PRODUCTS

VPlus Steam Joint and the VPlus ThermoBars ensure optimal dryer cylinder performance.

Value+ Steam Technology Optimization Package

New steam technology concept
improves drying process
A large portion of energy cost in the paper industry is incurred
Steam technology – the challenge

when drying the paper. Reducing energy consumption in the dryer

Energy savings		

section is therefore one of the most pressing tasks to increase theProduction costs
Environment		+efficiency of paper production. The new Value+ concept makessavings of up to 20% possible, depending on the system.

Value+ Steam Technology
Optimization Package
optimizes the drying process

Energy savings up to 20% with Value+.

22

26 I 2008 I Voith Paper I twogether

PRODUCTS

In the past the operating speed ofsteam to the wet paper, the drying

achieved where the drying process ismany paper machines was increased

cylinder dewatering and system in-the bottleneck in the paper productionin order to increase production. In thestrumentation.

process. The drying output is determined by the average difference bet-

process, the steam technology wasoftentimes not adapted to the new

Here, the drying is not purely a heatween the temperature of the roll sur-conditions. As a result, the specificconductivity problem but rather is af-

faces and the paper web temperature.

steam consumption often increased,

fected by other factors such as po-

This can be increased by raising thethat is, the ratio of the number of tons

cket air humidity and movement insteam pressure, making constructionalof paper produced and the required

the ambient air and pressure. Basedalterations or using condensate turbu-

quantity of steam increased and wason this all-encompassing analysis,

lence generator bars, which can in-

therefore less efficient (Fig. 1).

the optimum web drying is calculated

crease the drying output and resulting

and developed. The key element for

production speed at 1,000 m/min by

As a holistically-minded process sup-designing new as well as modernizedapproximately 20%.

plier, Voith Paper takes comprehen-systems is the process calculation

sive consideration of all aspects in-program which gives the plan of ac-

In contrast, insufficient evaporation

volved with the paper drying process.

tion a solid founding. The potential

can still reduce the speed despite highUsing this knowledge, we develop

reflux of capital consists mainly of sa-

heating. Saturated ambient air or acustom solutions as part of the Va-

ved steam and/or the increased pro-poor air exchange can interfere withlue+ Steam Technology Optimization

duction output.

the material transmission. The processassessment, combined with a broad

Package (Fig. 2). The following Vplus
Components make it possible to save

Saving steam can, for example, be

range of experience and dependable

energy, thus increasing the efficiency

achieved by reducing quantities of

hardware, makes it possible to designof the production process.

exhaust steam and better arranging

custom solutions that can reach amor-

dryer groups among each other. Fur-

tization in less than a year.

Optimizing the steam andther potential can also be found incondensate systemsteam-heated auxiliary consumers.

Vplus Steam Joints with

Their consumption can be reduced

stationary siphons

In order to modernize the system,

through a proper recycling of heat.

first an analysis is performed on-site.

Depending on the system, savings ofIn many current drying cylinders, theThis is mostly to locate weaknesses

up to 20% is possible. An increase in

dewatering is performed by steam

in the drying process, heat transfer ofthe production output can always be

joints with rotating siphons. To ensure

Speed

echnology Ana
lys
mT
ea

is

tea

ific sSpec

Energysavings
potential

St

on

mpti

nsu
m co

Vplus
Steam Joints

Specific steam consumption
state-of-the-art

1970

2008

Fig. 1: Energy savings potential in steam technology.

26 I 2008 I Voith Paper I twogether

ThermoBars
Stema
Eng m and Air Syste n
io
inee
p
ring and Ada t

Fig. 2: Value+ Steam Technology Optimization Package– tailor-made customer solution.

23

PRODUCTS

in the heat transfer while improving

30

Mini ThermoBars for the edge region

0.6of the cylinder have a positive effect
20

0.4
10

0.2
0

0
600

800

1,000

1,200

Blow-through steam in %Required differential pressure (bar)the moisture profile at the same time.
0.8

web.
Increasing energy costs reduce theefficiency of the paper industry anddemand action.

1,400

PM speed (m/min)rotating siphon

on moist edge strips of the paper

stationary siphon

Vplus components help to reduceenergy costs, thereby securing competitive advantages.

Fig. 3: Stationary siphons with low differential pressure and reduced blow-through steam
provide for reliable dewatering and optimal energy requirements across the entire rangeof speeds.

a reliable dewatering of the drying

maintenance-friendly thanks to theircylinder, the differential pressure mustlight, compact design. The necessary

be continuously increased with areplacement parts can be deliveredrising PM speed. At the same time,quickly and inexpensively ex-ware-

the blow-through steam increases

house.

(Fig. 3).
Vplus ThermoBars
Low cylinder pressures and increased
production speeds often even have

For production speeds greater than

the result that the cylinders cannot be

500 m/min, the condensate forms adewatered. As a result of the accom-

laminar ring in the drying cylinder,

panying decline of the heat transfer,which reduces the relative heat trans-

the drying capacity can drop mas-fer of the steam to the interior wall ofsively.

the cylinder.

Infobox:• Can be used regardless of paper type, forexample, with graphic papers, cardboard,
packing papers and tissue papers• For more information on Value+, please visit
http://www.valueplus.voithpaper.com.

Contact
Steam joints with stationary siphonsThermoBars break up this ring byfrom Voith offer an economical alter-creating turbulences to create an in-

native. They make for reliable dewa-

crease in the heat transfer and drying

tering at the lowest differential pres-capacity. This can increase the pro-sure. In addition, the blow-throughduction speed and output.

steam does not intensify with increasing speed and remains at the lowest

The custom planning of ThermoBar

level when the siphon diameter isinstallations in selected drying cylin-

optimized. Voith steam joints areders creates a precise improvement

24

Erich Willer
Paper Machines Graphic
erich.willer@voith.com

Holger FunkPaper Machines Graphic
holger.funk@voith.com

26 I 2008 I Voith Paper I twogether

Paper quality you can taste!
We come across specialty papers
in everyday life in many ways.
Learn more about them in our“Specialty Papers” special edition.

Voith Paper

Publication date: Sept. 2008
Order the magazine free ofcharge at:
specialtypaper@voith.com

PRODUCTS

IntensaPulper IP-V with double break bottom tank and eccentric rotor.

IntensaPulper now for recovered paper

Up to 25% energy savings
		
without sacrificing quality
With the new IntensaPulper concept, Voith Paper has taken anotherstep forward in saving papermaking costs. The IntensaPulper ismore efficient than conventional pulpers, not only for virgin fiber
furnish, but now for recovered paper as well. Furthermore, nearly
all LC pulpers can be retrofitted with Intensa technology.

26

26 I 2008 I Voith Paper I twogether

PRODUCTS

Up to 25% energy savings not only
sounds fantastic – it is nothing shortof revolutionary. Official recognition ofthis feat came in October 2007 when
Voith Paper was awarded one of thethree coveted Palmes de l’Innovation
at the ATIP trade fair in Grenoble,
France for the IntensaPulper design.
To achieve these enormous savings
without sacrificing quality, Voith Paper implemented some radical designchanges in the IntensaPulper IP-V for
virgin fiber furnish. These include
eccentric arrangement of the rotor in
the pulper tank and double breakbottom tank geometry for flow-optimized transition from the pulper floor
to the cylindrical tank wall. The sum
effect of these measures is not only
extremely intensive and faster mixing,
but also less energy consumption.
Savings for virgin fiber pulping

IntensaPulper IP-V in operation.

in the pulper tank instead of the foursa technology can be retrofitted toor six tank baffles normally used. This

conventional LC pulpers as well.

To put energy savings into perspec-

specially shaped deflector is desi-An “IntensaTechnology” upgrade kit,

tive, a virgin fiber capacity ofgned to minimize energy losses while

comprised of a rotor exchange or re-

100 tons/day processed using theeffectively directing the flow of stock.

build and flow deflector modification,

new Intensa concept under design

The rotor has also been technologi-

soon pays for itself with a very fast

conditions saves approximately

cally improved, resulting in more ef-

ROI – thanks to impressive quality

175,000 kWh per year or up to 25%

fective defibering and energy-saving

improvements and energy savings.

of the pulping energy formerly re-agitation even at high stock consi-

quired. Thanks to systematic applica-

stencies. Intensa technology is now

tion of this concept, the sameused very successfully in Japan fortechnology can now be used for LC

pulping recovered paper, and additio-

pulping of recovered paper furnish.

nal customers in Asia and Europe ha-

For pulping recovered paper, the In-

ve already ordered an IntensaPulper

tensaPulper flow characteristics had

IP-R for pulping recovered brown

to be modified even more radically.

grades.

The decisive difference lies in the

Advantages of thenumber and arrangement of theIntensa concept

tank’s stock deflectors. Since every
flow deflection causes energy losses,

All papermakers can benefit from thethe IntensaPulper IP-R for recovered

proven advantages of energy saving

paper furnish only has one deflector

and optimal agitation, because Inten-

26 I 2008 I Voith Paper I twogether

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

Jochen Krebs
Fiber Systems
jochen.krebs@voith.com

27

PRODUCTS

One less interface

Field instruments added to product portfolio
In the middle of last year Voith Paper Automation started theso-called Field Instrument Initiative to provide reliable support tocustomers and eliminate unnecessary interfaces in the area of field
instrumentation.
Field instruments are integral compo-

plants are often equipped with fieldnents of every paper machine anddevices from different suppliers,

make a decisive contribution to themaking coordination very difficult for

perfect functioning of a mill. However,the customer. Quotations have to be

On/off & control valves are available in two models: as a ball segment valve with the name “OnC SegmentValve” (left) or the“OnC DiscValve” butterfly valve (right).

28

26 I 2008 I Voith Paper I twogether

PRODUCTS

obtained and compared, orders have

On/off & control valves

to be tracked, and deliveries have tosuspensions, coatings, and chemical
additives. Due to the robust measu-

be checked: All of this uses up custo-

Thanks to cooperation with thering cell materials (special ceramics

mer resources and leads to a highSwedish company Somas Instrument

or stainless steel), the pressure trans-

number of interfaces.

AB, a manufacturer of high-perfor-

mitters can also be used at high tem-mance valves, on/off and control

perature or in aggressive media suchvalves are now part of the permanent

as sodium hydroxide solutions.

One partner for all needs

product scope. The valves are offered
Voith Paper Automation hence

in two different models: as butterfly

In addition, the special ceramics inexpanded its product portfolio andvalves and as ball segment valves.

particular feature high wear resi-

since the middle of last year has been

The latter have the advantages ofstance, making the transmitter ideal

offering a multitude of valves andbeing able to be installed in reject

for use in recycled paper stock pre-field devices. For this purpose, thepipes as well as in pulp and waterparation from pulping to the headbox.

company has built up partnerships

lines and working reliably up to a pulp

The wide selection of level and pres-with a number of firms that are allconsistency of 18%. Also, both valve

sure transmitters, which are distingu-

technological leaders in their respec-

types can be used for steam control

ished from each other by means oftive fields. By now there are alreadyand come in low-noise versions forthe measurement method and materi-approximately 60 products with

use at high differential pressures.

als used, ensure that the suitabledifferent variants being produced
exclusively for Voith and according

product can be found for every requiLevel and pressure transmittersrement.

selected the desired field instru-

Through a master supply agreement

Flow & temperaturements, Voith performs all further

with VEGA Grieshaber KG, Voith

steps up to product commissioning.

Paper Automation offers a compre-

Sensors for flow and temperature

Customers hence profit from guaran-

hensive range of level and pressure

measurement manufactured byteed delivery and constant high pro-transmitters. The transmitters have

KROHNE Messtechnik GmbH are

duct quality, which contribute tobeen adapted to the special require-also in the product portfolio. Like allsmooth, on-schedule start-up of thements of the paper industry and canpartner firms, KROHNE is a global

production line.

be used with water, steam, paper

leader in its field and is “either theto its design. After the customer has

Product name

Function

Cooperation withOnC DiscValve

On/off & control
butterfly valves

Somas

OnC SegmentValve

On/off & control ballsegment valves

Somas

OnC PressSens

Pressure transmitters

VEGA

OnC LevelSens

Level transmitters

VEGA

OnC FlowSens

Flow measurement(magnetic-inductive, vortex,
and mass flow)

KROHNEOnC TempSens

Temperature measurement

KROHNE

Overview of key products.

26 I 2008 I Voith Paper I twogether

OnC FlowSens flow meter.

29

PRODUCTS

market leader or at least in the top

tion, the number of interfaces was re-

For the papermakers, one of the mostthree for all its main products,” accor-

duced significantly and project com-

important ultimate advantages of theding to Stephan Neuburger, CEO atpletion greatly simplified. Throughinitiative is the combined expertise it

KROHNE. The devices for tempera-

this, customers profit from the lower

provides. Through cooperation bet-ture measurement integrated into

coordination efforts required, since

ween Voith Paper Automation andVoith’s product portfolio encompass

Voith takes over this task.

leading producers, customer wisheswith respect to new products orvarious types of sensors for use
along the entire production line.

Customers are additionally supported

product changes can be implemented

For flow measurement, two measure-in the selection of the appropriate

better and more precisely.

ment methods (vortex frequency andfield instruments to ensure that thesePeter Hägg, owner and CEO of So-

magnetic-inductive) and a device forare optimally coordinated to themas, summarizes as follows:mass flow measurement are availa-

plant. If changes are made at shortble. Here, too, this ensures that thenotice during the planning phase for“Thanks to Voith Paper Automation’s

right device can be supplied for every

a mill, Voith automatically adjusts thein-depth understanding of the paper-

possible application.

scope of supply of the field instru-

making processes, we will be able toments. In addition, delivery times andadvance development of our valvesa constant high product quality canwith focus on the paper industry andObvious advantages

be guaranteed. Through the instru-

on customer needs with Voith as ourA large number of installations world-

mentation provided by a single sup-partner.”wide guarantee the reliability of theplier, integration of the devices into

products. Initial results of use of thethe process control system is simpli-

Voith product series confirm the suc-fied and uniform documentation

cess of the Field Instrument Initiative:

enabled. Maintenance and replace-

The field instrument product portfolio

Through clear assignment of only one

ment parts stocking can also be

will expand even further. By the sum-contact partner for field instrumenta-

handled more efficiently.

mer of 2008, for example, sensors for

Outlook

ash measurement will also be available. A device that measures opticalconsistency is already included in the
product scope; it was developed byVoith for use in the paper industry.

Contact
Dr. Marcus True
Automation
marcus.true@voith.com

Selection, delivery, installation, and monitoring from one source:
inspection of the OnC PressSens pressure transmitter.

30

26 I 2008 I Voith Paper I twogether

PRODUCTS

SpeedSizer film press with Luna roll covers provides a constant film coating process.

LunaFilm and SolarCoat: The new applicator roll covers

The key to successful film coating
The film coating application is a complex process in which
many different parameters have to be considered. Applicator rollcovers have to be able to run reliably and consistently for long
periods of time and have to enable cost effective production ofhigh quality end products. To fulfill these demands, Voith Paper
Rolls has developed two new applicator roll cover families:
LunaFilm and SolarCoat.

26 I 2008 I Voith Paper I twogether

31

PRODUCTS

The paper industry employs film pres-to enable the formation of a homoge-features can provide the correct

ses for the production of coated andneous film which is transported to theselection for the roll cover.

sized paper in a broad speed range.

paper in the nip. The film transfer de-

The record-breaking production rates

pends on various factors, including:for packaging paper of 1,500 m/min

film coating composition, absorption

and for coated paper of 1,700 m/min

behavior of the paper, dwell time in

LunaFilm combines a new rubber

make high demands on the roll co-

the nip and nip pressure.

material with high quality fillers andvers. The applicator roll covers haveTo achieve an even coating color dis-fibers. Thus, the durability is increa-

a strong and decisive effect on paper

tribution and ideal runnablity of thesed, the abrasion reduced and the rollmachine efficiency and paper quality.

film press, the nip width should becover surface optimized for the parti-

uniform across the whole roll face.

cular case of operation. LunaFilm is

For coating applications, the nip

available in three different versions:Film application process

LunaFilm

pressure has to be lower to minimize
The film application process depends

the penetration of the film coating

LunaFilm S is the basic product ofupon various factors. The rod pre-color into the paper. In contrast, a

the new fiber reinforced Luna rubber

meters the amount of film applied onhigher nip load is required for starchcover series, which provides additio-

the roll cover. Hydrodynamic condi-

penetration.

nal impact/mark resistance against

tions under the rod, machine speed,

paper wads and wraps.

rod diameter, rod pressure, rod

Which roll cover is thegrooves, coating color solids as wellright one?

LunaFilm E is highlighted by enhanced

as the wettability of the cover, coverabrasion resistance. The typical rough-hardness and cover roughness all

Due to the various demands of aness value (Ra) is 1-1.5 µm. Uniform

affect the amount of film. The surface

paper machine, it is evident that only

film quality and stable web run areof the roll cover has to be designed

a broad product range with different

maintained over long running periods.

wear resistancechemicalresistancewear resistance

5

5

4

4

3
2

impactresistancedamage resistanceagainst dry friction

1

good web release/
low misting

Film sizing properties of LunaFilm.

32

impactresistance2
1

film quality

Conventional cover

3

LunaFilm S

good web release/
low misting

LunaFilm E

LunaFilm R

film quality

SolarCoat

Film coating properties of LunaFilm and SolarCoat.

26 I 2008 I Voith Paper I twogether

PRODUCTS

LunaFilm R provides the highestroughness. The higher initial roughness (typical Ra = 1.5-3 µm) is retained throughout cover life cycle. It isutilized when additional coating distribution/transportation onto the rollsurface is required, and/or additional
control of web release is needed.
SolarCoat
SolarCoat is a polyurethane coverwhich is specifically designed for the

Infobox: Benefits of LunaFilm and SolarCoat• Consistent film quality without rod splitting
due to optimized dynamic properties andsurface conditions•	Minimized process variations due to thermal
and mechanical stability during the run cycle•	Customized dynamic properties at the roll nip
enabling the desired transfer of starch/coating
into the substrate•	Optimized sheet release, consistent sheet run
and reduced misting due to customized coversurface and roughness•	Longer runtime and less unscheduled downtime due to improved mechanical stability andabrasion resistancefilm coating process. The excellent
wettability of SolarCoat provides best
coating film formation and splitting
characteristics. Misting is minimized
at very high coat weights and highContact
Max Albrecht
Rolls
max.albrecht@voith.com

machine speed. The high hydrolysis
resistance maximizes hardness stability. The resulting uniform nip conditions as well as stable web release

Sergio Giuste
Rolls
sergio.giuste@voith.com

ensure a trouble-free operation during
the film coating process.

SolarCoat is a polyurethane cover with excellent wettability providing best coating film formation and splitting characteristics.

26 I 2008 I Voith Paper I twogether

33

PRODUCTS

TerraGloss – the new hard calender roll coating.

The new thermal roll coating

Energy savings up to 30% due to TerraGloss
TerraGloss is the new thermal coating for hard calender rolls.
Numerous field tests have shown that the assembling of TerraGloss
leads to longer runtimes, partly even doubles it. Additionally, theline load and the heating energy can be reduced. This may lead toenergy savings of up to 30%.

Each paper has special

high gloss quality in a fast speed

demands

production process using an
abrasive filler content material.

The demands of the hard roll for ca-• For profile demanding speciality

lendering or smoothing of the surface

and art paper, often the caliper

differs in corresponding paper

must be corrected with high energy

grades. Consecutively a few attri-transfer systems like CalCoil andbutes are listed as an example:

Thermajet (auxillary heating
systems) in the calender.

• Packaging paper requires highsmoothness and moderate gloss• Decor paper reacts sensitively toheavily loaded thermo roll surfaces.

while maintaining the caliper.

34• Coated and uncoated magazine

The application of moisture/steam in

paper requires a very smooth,

front of the calender nip can free filler

26 I 2008 I Voith Paper I twogether

PRODUCTS

Operating experiencematerial at the paper surface andInfobox: TerraGloss benefits

intensely stress the thermo roll.
The performance of the calender

Application engineer Kurt Landerts-

can be advanced with TerraGloss.

hammer reports about the first appli-

Each desired paper property can becation experiences:improved. Besides the improved paper
quality, TerraGloss convinces through“On a high speed paper machine inbetter durability of the factor 10 rela-the LWC sector it was possible to re-tivly to chilled cast iron roll, depending

duce the heating energy of a thermal

on the single case. According to theroll from 1,300 to 900 KW with identi-

process demands, TerraGloss can be

cal calendering results. The reduction

doctored intensively, but can also bein energy usage yields a saving

driven without doctor blades.

potential of several 100,000 euros
each year.

Special production
In the Janus calender for the SC

know-howdepression production, the durability
TerraGloss is the result of innovationof the thermal roll could be doubled

and development: optimized material

with TerraGloss and the application of

on carbide and nitride basis, highest

the micro-abrasive doctor blade Voith

kinetic energy during the coating

SkyTop T.”

process and a special grinding. Voith
Paper developed a proprietary coating•	Reduced line load and heating energy at
equal or improved paper quality, therefore
energy savings up to 30%.
• High resistance against abrasion.
• Stability of the once adjusted surface
roughness.
•	High resistant to chemical and mechanicalimpacts.
•	Due to the high hardness grade (up to1600 HV), TerraGloss has longer runtimes.
•	The state-of-the-art finishing improves theshape accuracy permanently, therefore complex energy adjustments can be minimized.
•	Longer runtime of the thermal roll due toconstant surface roughness and minimalabrasion.
•	Positive impact on gloss and /or smoothness
through wide roughness range (0.02 µm and0.8 µm Ra).
•	Micro-abrasive doctor blades (SkyTop T)
can be used continuously.
•	Highest resistance against contamination of
the surface.
• Volume gentle calendering.
•	Best profile also at the hard-/hard-nip
without correction due to optimized grinding.

system, which is exclusively available
Contact

to our shops. The customized hardmaterial sizes, the selected filler matrix

Dr. Hasso Jungklaus
Rolls
hasso.jungklaus@voith.com

and the special finishing offer a compact layer of highest hardness andadhesion, which can be grinded to thehighest tolerance.

1,400
1,200
Ra[µm]

kW

1,000
800
600
400
200
0

Competitor

TerraGloss

0.35
0.33
0.30
0.28
0.25
0.23
0.20
0.18
0.15
0.13
0.10
0.08
0.05
0.03
0.00

Sulzer GD 03
DPC 169P

TerraGloss0

Example of possible reduction of heating powerwith TerraGloss at constant paper quality.

26 I 2008 I Voith Paper I twogether

500

1,000

1,500
Operating hours

2,000

2,500

3,000

Roughness process of the TerraGloss coating in comparison to competitors.

35

PRODUCTS

Web tension forces the lamellas of the WebTense roll cover to lie down and to the side – thus achieving the spreading effect.

WebTense lamella roll cover

Replacement of conventional spreader rollsin coaters and calenders
Until now, conventional spreader rolls were the only medium toprevent wrinkles in the web. Today spreader rolls in coatermachines and calenders can be replaced by the lamella roll cover
WebTense. The WebTense design creates new opportunities.

36

Papermaking is a challenging job.

paper machine. The paper adapts by

Massive amounts of high quality

shrinking or expanding to variations

paper must be produced on a consi-

of moisture, temperature and draw,

stent basis. Ideally, the paper web in

depending on the section it is pas-

the machine is even and smooth at all

sing through. But due to the fact thattimes; reality shows that this is not

the paper sheet is one single band,

always the case. Because the paper

the width cannot be changed arbitra-

sheet is pressed, dried and rewetted

rily. Variations in width lead to wavi-

again in the different sections of aness and possible wrinkles in the

26 I 2008 I Voith Paper I twogether

PRODUCTS

worst case. Spreader rolls counteract• Easy maintenance – no complex

these effects. This is a working princi-mechanical service of segmentple, but also goes hand in hand withbearings

high maintenance and service costs.

• Elimination of sealing and segment
bearing leakages

Conventional spreader rolls canbe replaced by rigid rolls• Energy saving – less drive capacity
necessary• Larger paper wrap angle (15°-180°)
Thanks to the WebTense lamella rollpossiblecover, conventional spreader rolls in• Less space required because thecoater machines and calenders can beconventional spreader roll, up- or

replaced by rigid guide rolls today.

downstream guide roll, can be

WebTense is applied to a rigid steel roll
(EvoRun) or carbon fiber composite roll
(CarboRun). Web tension forces thereplaced by WebTense• Vibrations can be eliminated withthe use of CarboRun

lamellas to lie down and to the side,

Depending on position and applica-

thus achieve the effect of spreading

tion, WebTense reaches a life time ofthe sheet. Depending on the specific

one to several years. The cover must

application, WebTense can be made of

only be replaced when the lamellasrubber, polyurethane or high tempera-

lose their elasticity and thus diminish

ture resistant rubber.

the spreading effect.

The advantages of WebTense

Replacing a conventional spreaderroll with WebTense needs some

There are many advantages of repla-

engineering work. The web guidancecing conventional spreader rolls withand the specific demands have to be

WebTense.

exactly analysed. The design of the• A simple construction – a rigid rollroll cover has to be tailor-made forcore instead of multiple segments

Max Albrecht
Rolls
max.albrecht@voith.com

each application.

WebTense can be made of rubber, polyurethane orhigh temperature resistant rubber.

26 I 2008 I Voith Paper I twogether

Contact

Deformation of the cover in radial direction.

37

PRODUCTS

PrintForm HS: High paper quality at high speeds.

Newsprint paper at the highest speeds and of excellent quality

Development aimed at meeting multiple customer goals
How can the continuously increasing demands for paper quality be
met? Where is there potential for optimization?
Paper manufacturers and forming fabric producers are trying toprovide an answer to this question.
Decreasing growth rates in the paper

On the contrary, quality demands aremarket through recent years are

increasing steadily.

responsible for the constantly increa-

38

sing pressure for quality and cost red-

The forming process poses immense

uctions expected from paper produ-

challenges for both machine builder

cers. Reducing the raw material andand fabric producer and there are aoperating costs as well as maximizing

variety of factors that contribute to

the machine speeds and efficiency arethis. Shearing forces and degree of

therefore the prime goals of paper ma-

turbulence must be controlled just as

kers. Today the market allows for no

precisely as the filtration and thicke-

compromises in quality whatsoever.

ning processes. The retention of solids

26 I 2008 I Voith Paper I twogether

PRODUCTS

must remain stable and at adequate

exception of the outermost surface

levels to limit the consumption of che-layers, are now formed.

• Improved surface topography ofthe fabric is necessary to enhancemicals. In addition, drainage control is

the surface roughness and visualtargeted to prevent sheet sealing or

Dewatering through the forming

hydraulic sheet forming defects.

fabrics produces a fiber mat on theproperties of the sheet.

For the ideal formation and control of

paper side of the woven surfaces:

Both of these quality criteria must

two-sidedness in the counter blade of

Step one of sheet formation. Here, thealso be considered in combination

the former, the condition of the outerscreen design plays an important rolewith other machine sections, whichlayers of the sheet as well as the re-in the sheet forming process.

also have significant effects on themaining fluid core have to be adjusted

sheet.

carefully.

What requirements does the
The basic requirements for a consi-

forming fabric have to meet?
The magnitude of this challenge beco-

stent sheet structure, good formation,

mes clear when considering the time

They must contribute to improved

minimal marking by the forming

required to form the sheet. In the casepaper quality under the extreme

fabrics have to be met in terms ofof a modern, high speed paper machi-

conditions of the paper machine.

sheet quality. The speed-specificne, 75-80% of the stock volume is al-

For publication grades such as

requirements include the lowest

ready dehydrated, that is, the water isnewsprint or LWC a high percentage

possible water transport by theseparated from the fibers after appro-of waste furnishes are used:

forming fabric and adequate lifetime.

ximately 20 milliseconds. After anotherToo much water transport by the

40 milliseconds, the sheet has already• Improved dye absorption or color

forming fabrics at high machinereached the point of immobility, mea-

penetration, an important quality

speeds would result in a heavyning that the fibers have reached theircriterion of printed paper, requires adischarge of water and soiling of the

final position in the sheet. The main

highly symmetrical and densified

machine which can seriously effectproperties of the paper, with the

sheet structure with a low porosity.

runnability efficiency.

Drycontent after former 20.3%

Drycontent after former 19.8%

6%

3%
3%

3%

6%
38%

5%
12%

10%

42%

35%
100%

Dewatering benchmarked with super fine SSB.

26 I 2008 I Voith Paper I twogether

37%
100%

Dewatering with PrintForm HS.

39

PRODUCTS

PrintForm HS

ment to a customer's machine, in order

testing points with different settingsa developed solution

to assess a large number of operatingof vacuum, blade pressures andand quality parameters. These include,

jet-stock speeds.

The achievement of high paper quality

on the one hand, the direct properties

at higher paper machine speeds wasof the forming fabrics, such as CD andthe goal in developing a new type of

MD dimensional stability, or the water

forming fabric. The result is thetransport and associated cleanliness

The machine speed was 1720 m/min

PrintForm HS and its impressive tech-of the machine. On the other hand,on the former. The PrintForm HS andnical specifications. With a Fiberprocess behaviors such as dewateringreference fabrics had identical perme-

Support Index (FSI) of up to 235 andand retention, as well as the actual

ability were run through all trial points.

over 1,800 support points per cm², it

paper quality attributes of formation,

is not only the finest fabric but with aporosity, sheet structure, surface andPrintForm HS trials produced consi-

caliper down to 0.58 mm it is also

strength properties.

derably better mechanical retention

thinner than most two-ply fabrics.

Newsprint paper trial

behavior. The retention of both fiber
PrintForm HS was tested producing

and ash are shown in the retention

PrintForm HS, which is used in thenewsprint paper under different trial

diagram below indicating potential

TQv former on both inner andconditions at the PTC using 100%savings in the retention chemistry,outer positions, should make a consi-

waste paper base.

a significant advantage to the paper-

derable contribution to solving the

The test series was carried out on the

maker. One of the key development

aforementioned problems but can only

DuoFormer TQv, for which conventio-

targets for the PrintForm HS was its

be proven by practical testing.

nal forming fabrics were used as aability to perform at high speed. The

Voith Paper Fabrics tests its machine

benchmark for the PrintForm HS. In

PTC trials included a test, producing

clothing on test paper machines suchorder to test the fabrics in the entire

Newsprint up to 2,500 m/min. Even atas the Paper Technology Center (PTC)

production window of the paper ma-

this very high speed, the dewateringin Heidenheim before the first deploy-chine, the trial plan included multiple

behavior remained stable, the dry

85

*

75

*

Retention (%)

65

PrintForm HS
Standard

55
45
35

*

25
15
7,000

*
8,000

Fiber retention
Total retention
Ash retention

**
9,000

10,000

HB flow (l/min)40

11,00012,000Compared tostandard fabric:
Higher retentions with
PrintForm HS and
10-40% less retention
aid dosage.

26 I 2008 I Voith Paper I twogether

PRODUCTS

Surface Roughness

highReduction of sheet
two-sidedness > 50%

lowStandard super fine SSB

Bottom fabric: PrintForm HS
Top paper side
Bottom paper side
Target for max. roughness

Improvement of theroughness with
PrintForm HS.

content after the former remained justposition, was the key criterion for theas high and there was minimal water

fabric trial. No design changes weretransport or discharge, the clear

made to the top fabric. A considerable

advantage of this new design. This

improvement in the roughness on theoutcome and other results for otherbottom fabric side of the paper allo-

material qualities provided the basis

wed the two-sidedness to be reduced

for the field experiments.

by approximately 50% and the goal of
the papermaker to be achieved.

The ultimate test at thecustomer's site

Conclusion

Building on the experiences gained

The close cooperation between paper

at the PTC, the application teammakers, paper mill suppliers andreviewed the PrintForm HS ahead ofclothing manufacturers allowed for an

its first test on a customer's machine.

ideal definition of the target require-

The target was to reduce the sheetments for this forming fabric. In the

two-sidedness on a fast-running

PTC, the PrintForm HS was able togravure paper machine.

achieve the stated goals to improve
paper quality and increase machine

The customer traditionally ran very fineefficiency — and this at machine

weft-bound SSB fabrics though the

speeds of up to 2,500 m/min.

paper roughness was still above the

The application of the PrintForm HS

required value on the bottom side ofto the customer offered impressive

the sheet. PrintForm HS with a 30%

proof that the trial results from thehigher number of support points, com-

PTC are transferrable to full produc-pared with the standard fabric in thistion machines.

26 I 2008 I Voith Paper I twogether

Contact
Thomas Rühl
Paper Machines Graphic
thomas.ruehl@voith.com

Matthias Höhsl
Fabrics
matthias.hoehsl@voith.com

41

PRODUCTS

The eight shaft structure on the machine side.

PrintForm HR – Developed for "hybrid"
formers such as the DuoFormer D.

Forming fabric PrintForm/MultiForm HR

Forming a quality sheet on a robust fabric,
the perfect combination
Type HR forming fabrics create new possibilities for paper andboard producers: they provide long life potential and contributedecisively to paper quality.

The PrintForm HR has proven itself to

The development process

be versatile in terms of the paper
grades it produces and the machine

There is a growing number of Hybrid

configurations on which it can run.

formers used in the market. The Duo-On graphical grades, its successes

Former D produces a wide range ofinclude a growing number of Hybrid

graphic paper grades often with large

formers, often prolonging the fabricamounts of abrasive fillers.

life despite the increased use of abrasive fillers and high forming blade

Visual and surface printing properties

pressures.

are increasingly critical in the Board& Packaging sector, for example on

In the packaging sector the Multi-

bleached, folding box and white lined

Form HR has regularly performed atchip boards.

speeds over 1,300 mpm on gap for-42

mers, its robust structure standing up

High-speed gap formers, such as theto the extreme drainage conditions.

DuoFormer Base, produce packaging

On board machines, MultiForm HR

grades that require fabrics with incre-

has produced some of the most criti-

ased stability that also counter pres-cal grades in the world in terms ofsure from extreme water flows yetsmoothness and visual properties.

maintain solids in the sheet despite

26 I 2008 I Voith Paper I twogether

PRODUCTS

5-Shed vs. 8-Shed

Open warp structure and sheet support mechanism.

Paper side (top) and machine side (below),
both as 3:2 ratio.

the increased use of shorter recycledof an open warp and denser weft has

machine side, the HR has an increa-

fibers.

shown that drainage can be opti-

sed the float length by 7.6% compa-

mized through maintaining an open

red to the 16 shaft multilayer and

The industry required a robust Sheetsurface area and that retention can

9.3% from a conventional SSB having

Support Binder (SSB) fabric which

be improved through improved brid-a five shaft machine side weave.

provides a wide operating window forging of the MD-orientated fibers.

paper quality, clean running and pro-

The PrintForm HR takes this concept

longed running time. The develop-

to the next level. Maintaining an open

ment targets for such a fabric were:

warp structure allows increased pa-

Benchmarked against a fine five shaft

per side CD yarns and maximum

SSB design with similar permeability

sheet support.

and machine side yarn diameter, the• Increased resistance to abrasion
on the machine side• High-drainage capacity but withexcellent CD stability.

Benchmarking the project

HR matches sheet support properties
The open warp structure also allows(SP & FSI) on the paper side.

coarser yarns on the machine side

The yellow colored squares show the• High-sheet support, similar to theincreasing the stability and resistancepaper-side structure of the HR is clo-levels seen on “fine” SSB designs

to abrasion through improved warp

se to the benchmark whilst the ma-burial. The use of 16 shaft structureschine side is more robust. The combi-

The PrintForm HQ is already provenhas been used to good effect innation of larger yarns and the eighton graphic machines often at world

multilayer fabrics to increase their life.

shaft structure provides increased re-record speeds. The design concept

Using an eight shaft structure on thesistance to CD bending stiffness. The

26 I 2008 I Voith Paper I twogether

43

PRODUCTS

Abrasion Resistance Index (ARI)

design speed of 1,300 m/min theshows the potential for extended

machine produces graphic paper.

Customer Comment
Jason Macreadie

running life on the machine.

Superintendent,

PrintForm HR provides controlled

Amcor Botany B7

dewatering on the bottom forming

Benefits to the customer

position ensuring ideal stock consiThe target features of the fabric werestency into the DuoFormer D andachieved. The range of variables

contributed to excellent formation

includes different weft ratio and weftresults. The robust fabric structureyarn diameters which allow thecontinues to increase the life potenti-

In Australia, Amcor Botany B7 is a

design to be considered for a wide

al and the last fabric, having achieved

Fourdrinier machine producing corrugating

range of applications. The benefits toa record life, had a further 20%

medium. It has specific needs in terms ofthe customer are:remaining from the laboratory report.

controlled dewatering in the initial formingzone and low draws off the couch. Jason• Exceptional retention of solids and

The PrintForm HR on the bottom

Macreadie, B7 Superintendent states,

minimum marking through the highposition is run in combination with

“The trial period gave improvements in all

sheet support

the HQ on the DuoFormer.

required categories, the greatest being

This combination is said by theformation. There was a step change inof different weft ratios which cancustomer to provide improved two

runability and a reduced couch draw

control the dewatering

sidedness and first pass retention.

gave the ability to go faster.

• Unparalleled formation through use• Long life potential through the

The fabric was removed as planned andeight shaft yarn float and larger

the life met our expectations. The technicalConclusion

assistance leading up to the trial ensured

diameters on the machine side• Solid sheet profiles throughThe demand for PrintForm andsuccess of the MultiForm HR. Overall a

improved resistance to CD bending

MultiForm HR continues to grow atvery successful trial which has now

stiffnessan exceptional pace and its versatility

become the benchmark.”

is benefiting a wide range of applicaProof of the benefits

Contact

tions.

Carl J. Taylor
Fabricscarl.taylor@voith.com

Yanzhou Zhongtian China started up
their PM 21 with a Voith DuoFormer D,
in March 2007 with Voith clothing on
all sections of the machine. With a

Benefit weighting

Development target compared to the benchmark SSB.

100

Benchmark SSB(Fine structure)

80
60

PrintForm HR

40
20
FSI

44

Open Area PS

Void Volume

Caliper

CD-Stability

ARI

Support Points

Fabric property

26 I 2008 I Voith Paper I twogether

PRODUCTS

Wood fibers are separated and prepared.

Pulp is delivered to the paper mills as pressed sheets.

Clothing for pulp drying machines are in a different class

Definitely heavyweight!
Voith Paper Fabrics offers a complete product platform for all types of pulp drying applications fromconventional forming and press sections to the most modern machines available in the market.

Did you know that more thanhemp, kenaf and bamboo fibers.

Market pulp is dried on a pulp drying

one-third of the world’s market pulp

The resulting substance, called pulp,

machine and sold as raw material toproduction is made on clothing fromis formed into thick sheets and trans-

the paper and board industry. The

Voith Paper Fabrics?

ported from the pulp mill to a paper

global pulp production on the othermill.

hand includes all pulp production,

Let’s start from the beginning withSide products such as chemicals andintegrated mills and market pulp.

some facts about market pulp.

water are recycled. The “black liquor”

What is market pulp and how is it

is used for energy generation.

The pulp industry is still dominatedgained?

Optimization has reached a stage

by North American mills, but thewhere the excess energy produced isstrongest growth rates can now be

Pulp is wood fibers that are separa-sold to the regular market. Somefound in Latin America and Asia withted and made suitable for paper andchemicals are recovered for re-use in

their warm climates that favor fastboard production. The pulping pro-the pulping process and also for theplant growth. Worldwide production

cess separates individual fibers bycosmetic industry.

volume reached 54 million tons inmechanical, chemical or semi-chemical methods. Most of market pulp is

2006, and market analysts expect
Market pulp production

chemical pulp. Pulp is mainly produ-

continued growth of about nine million
tons per year for the foreseeable

ced from wood but alternative materi-It’s important to separate market pulp

future. All market pulp is not createdals are continually being sought, e.g.

from the global pulp production.

equally; different raw materials and26 I 2008 I Voith Paper I twogether

45

PRODUCTS

Infobox: Cell Plattform-Highlights
CellForm N …

production processes result in

product group for broke conveyors

different products, as shown in theand threading tapes.

table below. Production capacity… is a triple weft 14-shaft design for:• controlled drainage for optimal function andimproved retention• additional pulp side support yarn gives very
good sheet support• three weft system ensures excellent CMD
stability• high wear potential due to long weft floats
on the roll side

Vector technology …
… is a tri-axial non-woven base fabricstructure. Its elasticity in all three directions
is important for resisting compaction andimproving fabric life.

meets the increasing demands.

Customers have very positive results
by using the full range of products

The heavyweight classavailable. “The Voith Cell Platform
helped CMPC Santa Fé to set a new

The basis weight of a pulp sheet canworld production record for bleachedvary from about 800 to 1,300 g/m²,

eucalyptus pulp at its mill in Chile,

compared to a sheet of copy paper

just six months after startup.

that is about 80 g/m², and can be

The PM 2, a 10 m wide machine,

produced at speeds of 100 to

produced 2,739 tons of pulp ADMT

230 m/min. Dewatering takes place(air dry metric tons) in a 24-hourin three stages resulting in a dryness

period. The machine was clothed

level of about 90%: having reachedwith CellFlex V3 and CellForm OP

30% after the first stage, the forming

during the record-breaking run on

section, the press section and the

30 May 2007.“

third stage, the air-floated dryer haveto manage the other 60%. In other

CellFlex V3 and V4 …

CellForm forming fabrics

words, 72 kg of water per square… are all mono based structures combinedwith single and double Vector components
respectively. The concept is well-proven
where high dewatering and good compaction
resistance are required. The Vector component
also significantly improves fiber locking whichis particularly beneficial for improving the
integrity of seam fabrics.

meter have to be removed during

The CellForm group includes well-these three stages.

proven designs that are capable ofhandling the requirements in the

The final process in pulp drying isforming section.

cutting of the pulp sheets and sheetbaling. A new, modern pulp drying

Voith Paper Fabrics reduced vacuum

line can produce up to one million

levels that were too high, resulting intons of production output per year.

lower energy costs, and eliminatedCellFlex V6 …

quality issues caused by uncontrolled… is a laminated all mono 2+2 design
including double Vector structure offering
exceptionally high compaction resistance anddewatering capacity. The strong construction
also provides very high tensile strength. It may
be supplied with double seams for safe andeasy installation.

The Cell Platformdrainage and insufficient sheet
dryness. These problems were all

The Cell Platform concept offers thesolved to full satisfaction by applying

CellForm product group for forming

CellForm N.

fabrics, the CellFlex product group

This fabric design was able to control

for press fabrics and the CellTech

drainage and increase sheet dryness,

Supplied capacity

46

Softwood		

20

Hardwood		21

Sulphite		1

BCTMP		

2

DIP		

3

Total		

47

Fig. 1: Supplied market pulp in 2006
by grade (million tons).

26 I 2008 I Voith Paper I twogether

PRODUCTS

while stabilizing the vacuum level andCellFlex press fabrics

thereby reducing energy consumption. The optimized machine equipped

The CellFlex group offers presswith CellForm N achieved record

fabrics for all types of pulp pressing

production.

applications. Voith’s well-proven

Customer Comment
Alan Ruiz
PDM Superintendent
from Arauco, Valdivia
mill in Chile

Vector technology – a tri-axial,
FormPress fabrics

non-woven base fabric structure – isthe basis for meeting the challenges

FormPress refers to forming sectionsin the respective press section.
“We are getting important additional

where a combination of forming
and pressing takes place requiring

The Vector series for pulp includes

benefits using this new concept. Following

special fabrics. A recent innovation

CellFlex V3, V4 and V6 in bothVoith Paper Fabrics’ recommendations,has been a combination of standard

endless and seamed versions.

we reduced HPS pressure to 600 kPa

twin-wire forming equipped with a

CellFlex V4 is a new development

and operated the showers only one hourpre-press and a shoe press.

including a high capacity base weave

per day instead of continuous. ThisThe bottom tandem wire in thewith double Vector components on

resulted in an increase in fabric life fromforming section also passes througheach side of the woven base fabric.

90 days to 220 days on 2nd and 3rd

the presses.

CellFlex V4 has improved dewateringpress, but the most important benefit has

capacity and improved compaction

been the reduction in water required to be

The FormPress fabric CellFlex ZC

resistance. The open structure offers

processed in the water treatment plant,

Seam is Voith’s solution for the bottom

high dewatering with lower vacuum

improving environmental conditions.”

wire, the most challenging position.

levels and requires less chemicalThis type of application requires

cleaning.

strategically engineered fabrics that

Customer Comment

can survive in the tough environment.

Voith Paper Fabrics’ new concept for

Jorge Reyes

Specially developed polyamide ispulp pressing, CellFlex V6 seam, isFiber Line Manager

used to withstand exceptionally highcurrently performing well in a very

CMPC Santa Féloadings in the shoe presses. Benefits

demanding shoe press position inseen with CellFlex ZC in the bottom

Finland, with greater resistance towire position are high performancechemical degradation.

and energy savings. In daily operation
the fabric achieved remarkably good
dewatering, resulting in 32% energy
savings and in addition, 13.8% steam
reduction at the machine.

“Just 6 months after startup, PM 2
achieved record production thanks to
Voith's clothing.“
Contact
Fredrik Ewalds
Fabrics
fredrik.ewalds@voith.com

Antonio Pereira
Fabrics
antonio.pereira@voith.com

26 I 2008 I Voith Paper I twogether

47

PRODUCTS

Nipco roll – in successful use for over 30 years

The “heart” of press and calendering technology
Fluctuations in the CD profile of the paper or board web are a thornin the side of papermakers. In order to guarantee a consistent, highquality paper grade to be continually processed and sold, thesefluctuations must be kept to a minimum. Due to the increasing
requirements of processors, the correction of CD thickness variations is becoming increasingly important.

A constant, flawless production result

the “heart” of press and calenderingis the basic requirement for competi-

technology. Thousands of Nipco rolls

tiveness in the international market.

are now in use. And the area of use

For targeted profiling and leveling out

for Nipco technology goes far beyondof the surface, Voith offers a variety ofthe papermaking sector.

tools in a wide range of perfor-

The focus is on tailored solution con-mances. This includes profile rolls,

cepts for operators. Modernizations

especially the Nipco roll. The basicof the existing Nipco technology pro-idea for today’s Nipco technology

vide a wide variety of product advan-

was developed in 1971. Just three

tages in efficiently rebuilding existingyears later, the first Nipco roll was

Nipco installations with the latest

operating in the press section of atechnology and improved characteri-

paper machine. This started the suc-stics. NipcoScoop, NipcoSeal, andcess story of the Nipco roll, which is

NipcoCool are just three of numerous

often described by papermakers as

upgrade options.

Hydrein roll in the rebuild to
the Nipcorect roll.

48

26 I 2008 I Voith Paper I twogether

PRODUCTS

The same Nipcorect roll in the rebuild to counter support elements.

Nipcorect roll

forces. So that a high profiling potential could be guaranteed, there was a

One example of constant continuing

conversion to counter support sour-development and the resulting mo-

ces that introduce a uniform force op-dernization is the Hydrein roll in a soft

posite to the working nip. To achieve

calender from 1989. In order to keep

the desired low line load, the suppor-

pace with required improvements inting elements are provided with sub-technology, it was converted to thestantially higher pressures in the nip

first Nipcorect roll in 1995. Since

direction than the conventional Nipco

then, Nipcorect rolls offer the opera-

rolls. The corresponding interaction

tor an enormous correction potential

between both supporting elementsin the CD profiling of the paper web,rows results in the always available

because the supporting elements incorrection potential between the indi-

this type of roll can be individuallyvidual zones even at low line loads.

controlled. Thus, a more precise fine
profiling is possible.

True to the motto “engineered reliability”, the deflection compensating

In 2007, the rolls that had been con-rolls from Voith allow a smoother andverted to Nipcorect were modernizedthus higher-quality production of pa-

again and adapted to the current de-per or board through the correction ofvelopments. The reasons for this are

CD profile fluctuations and thus acertain paper grades with a large per-crucial and reliable contribution to the

centage of recycled paper, which

productivity and efficiency of the ma-

were run in the lower range of linear

chine operator.

26 I 2008 I Voith Paper I twogether

Contact
Daniel Weber
Finishingdaniel.weber@voith.com

49

PRODUCTS

Fig. 1: New threading conveyor PrevoThread C.

Successful start-up of the new threading systems

Prevo – the new threading process technology
With the Prevo product line for threading solutions, Voith has fully
integrated the know-how behind the former Fibron technology andadapted and developed the product range to meet customer needs.
Due to a close cooperation between the Paper Technology Center(PTC) in Heidenheim (Germany) and the experts from Krefeld(Germany), a new product portfolio has been developed that covers
every threading process in paper and board machines.

50

26 I 2008 I Voith Paper I twogether

PRODUCTS

The product transfer from Vancouver

product family (Prevo), function level

Each additional zone of the conveyor

to Krefeld has been successfully(Fig. 3) and product level. Thus, thethen independently fixes the tail withaccomplished. Further researchthreading products are now uniformly

maximum vacuum.

and development work has led toand universally named.

• Optimum vacuum distribution for
the threading processadvanced and optimized design of all

assembled and tested in Krefeld andOne highlight of the new PrevoThread• Significantly reduced air consumption• Wear-free Venturi amplifier• Significantly lower noise emissiondelivered to customers around theC threading conveyor is the creationin comparison to previous vacuum

world. An assembly shop wasof vacuum with Venturi amplifiers.

sources

opened for this purpose and the

The Venturi amplifiers create a highproduction has started in December

vacuum along the entire length of the2007. All key components are

threading conveyor at a comparably

available on stock in order to realize

low air consumption, which can be

PM speed: 1,000 m/min

short delivery times. In addition,

switched off immediately. By dividing

Product: Liner and fluting

new developments and customized

the threading area into individual

Basis weight: from 90 to 220 g/m²

solutions can be tested in the PTC.

vacuum zones, the maximum vacuum

Vacuum technology

threading products. The threading
components are now manufactured,First successful projects

is achieved as soon as one zone is

The first order came from Kappa

covered by paper. The first zone is

Smurfit Roermond, Netherlands.

equipped with 4 Venturi amplifiers

The threading system to the Speed-

As part of the product revision, a new(Fig. 1) and generates a particularly

Sizer has been upgraded in the Voith

naming structure has been definedhigh vacuum, thus immediately

PM 3 from 1969. The new Prevo system(Fig. 2). It is divided into three levels:

stabilizing the incoming tail.

threads the tail without any problems.

Prevo product family

Prevo

Product family

Cut

Lift

ThreadRope

Function level

RR

FT

C

S1-120

Product level

TR

FTE

LT

S65-90DC

MDSF

H5-200

etc.

etc.

etc.

etc.

Example:Before:Current:

Function level

PrevoCutCutting the tailPrevoLift

Lifting the tailPrevoThread

Threading the tailPrevoRope

Rope system components

FlipTray
PrevoLift FT

Fig. 2: New naming structure for threading systems at Voith.

26 I 2008 I Voith Paper I twogether

Fig. 3: Elements of the function level.

51

PRODUCTS

PM speed: 9
 50 m/min(in future 1,250 m/min)
Product: Base paper for coatedPM speed: 1,750 m/min

sely balanced components. Prevo

Product: Newsprint

products provide the optimum soluti-

Basis weight: 48 g/m²

on for lifting, cutting and threading

wood-free printing paper
Basis weight: from 48 to 90 g/m²

the tail for all paper grades in any
At UPM-Kymmene in Steyrermühl,

position in the paper machine. All

Austria, a wet-end threading conveyor

future orders and rebuilds in existing

Another order came from a customer(PrevoThread CP) was installed bet-

paper machines will be equipped within Germany.

ween the 3rd and 4th press on thethe new Prevo systems.

The threading systems in the Speed-

PM 4 by the customer for the first timeSizer and End Section were equippedin August 2007. The quote from

Infobox: Prevo product family benefits

with the latest threading solutions in

Dr. Marco Lesiak, production manager

order to be able to thread throughon the PM 4, speaks for itself:

these difficult sections faster and“With the PrevoThread CW, we were

• Fast and safe threading systems• Stable tail guidance• Continuous threading processes

more safely. The following products

able to reduce our threading times inwere used:

the press section significantly. Our
experience so far has far exceeded• 4 PrevoThread C (Conveyor)• 2 PrevoLift FT (FlipTray)• 2 PrevoCut STC(SingleWaterTailCutter)our expectations. We are absolutely
thrilled with the results.”

Contact
Guido Royla
Finishingguido.royla@voith.com

A high cost-effectiveness for paper
production is provided by the fast andreliable transfer of the paper after a

The system of the new Prevo threa-

machine stop or sheet break. With theding products achieved outstanding

Prevo product family, Voith is offeringresults.

a reliable transfer concept with preci-

Philippe vom Bauer
Finishingphilippe.vombauer@voith.com

Fig. 4: Prevo threading solution on the PM in the SpeedSizer section (left: operating position; right: successful hit).

52

26 I 2008 I Voith Paper I twogether

PRODUCTS

Thanks to the Atmos development, high grade premium tissue can now be produced with considerably less consumption of energy
resulting in lower cost and less environmental impact.

Voith Paper Sao Paulo develops new process to production maturity

Atmos: fresh wind for tissue paper
For more than 30 years, premium tissue production depended on
Through Air Drying (TAD) technology, but not any longer. Thanks to
the Voith Atmos process, premium tissue can now be produced withmuch less energy and fiber outlay.

26 I 2008 I Voith Paper I twogether

When at the end of November 2007

gest papermaking concern Compañía

dozens of mother rolls of soft white

Manufacturera de Papeles y Cartones

tissue paper were loaded in Talagante(CMPC) – everyone was delighted.

tissue mill – belonging to Chile’s big-

The new tissue machine had com-

53

PRODUCTS

pleted its last series of test runs suc-protect the sensitive facial skin.

per quality, a process known as

cessfully. Now the papermakers had

These requirements can only be met

Through Air Drying (TAD) was develo-

the final proof that high grade premi-

if the tissue has enough bulk but isped about 30 years ago whereby hot

um products for the tissue market

still thin, airy and porous. With basis

dry air at more than 350 °C is blown

could be produced at lower cost, withweights of only 10 to 40 g/m , tissue

through the tissue web and structured

considerably less consumption of en-

papers are the lightest grades of all.

fabric on a large additional drum in theergy resulting in lower cost and lessBut manufacturing such soft and airytissue machine. Since however hot air

environmental impact. The Atmos

grades is certainly not easy.

alone does not make the tissue soft2

process developed by Voith Paper

enough, the paper is first sucked on to

Sao Paulo research engineers lives

Flat pressed sheets instead ofa structured fabric while still wet. Thisup to its name – Greek for vapour –airy tissue

imparts it with 3-dimensional structureby breathing fresh air into the tissue

before being dried in hot air. Pressing

production market. Furthermore, for

Airiness and softness is destroyedis largely avoided thereby, so that thethe first time in almost 30 years, an

above all by papermaking processes

paper remains soft and airy. Above all

innovative process has been matured

that press water out of the paper

the absorptive capacity of TAD tissue

to open up a new epoch in the pro-web. The originally voluminous andwas much higher than ever achieved

duction of soft lightweight tissue.

airy fiber mixture is compressed the-previously: paper towels made of thisTissue papers have quite different

reby – often at 30 bar or more – into atissue were able to absorb fifteen

characteristics to those of otherflat sheet of paper that is neither ab-times their own weight in water, twice

grades. Paper towels have to be ab-sorbent nor really soft. Although thisas much as conventionally produced

sorbent while at the same time strong

kind of paper is creped as it comestissue.

enough not to tear when wet. Toilet

off the Yankee cylinder to seem more

paper must be soft, and paper hand-voluminous, its characteristics are not

Although TAD technology has been

kerchiefs have to be even softer tochanged at all. To improve tissue pa-

continuously improved since then,energy cost rises above all in recent
times have made it too expensive.
As a result, tissue mills using TAD
machines are faced with shrinking
profitability. For this and otherreasons, Voith already decided someyears ago not to manufacture TAD
tissue machines. Instead, the Voith
Paper São Paulo development engineers followed another path. Theirgoal was to produce high quality
tissue with much less energy andfiber usage. Together with their Voith
Paper Fabrics colleagues, they finally

Atmos test runs successfully completed. Beaming faces surround the tissue machine in
the Talagante mill in Chile.

54

reached this goal with the Atmos
process.

26 I 2008 I Voith Paper I twogether

PRODUCTS

Talagante paper mill belongs to Chile’s
biggest papermaking concern:
Compañía Manufacturera de Papeles y
Cartones (CMPC).

Vacuum instead of hot air

saves more than 20% fibers comparedtissue. This flexibility is very valuablewith tissue produced on conventional

to CMPC, because so far the demand

The key element of this system is amachines. Nevertheless, its absorption

for particularly soft premium tissue invacuum roll over which runs a spe-and strength are the same. And sinceSouth America is not nearly as highcially developed fabric named Atmos-

the Atmos process does not need lar-as in North America or Europe. And it

Max supporting the tissue web. As inge quantities of extremely hot air, it

only takes less than eight hours to

the TAD process, this fabric is struc-consumes considerably less energy.

convert the machine.

tured to impart a 3-dimensional struc-

Furthermore, capital investment costs

ture to the tissue web. But instead ofare much lower than for TAD machines

Not only the Voith engineers are enthu-

hot air drying, the tissue web runs

because no big components (burners,

siastic about this new development,over the vacuum roll, which sucks out

blowers and large piping) are required

but also our customers. In the opinion

the water at about half atmosphericfor providing hot air. TAD tissueof Talagante mill manager Arturopressure. The structured fabric andmachines can only achieve superior

Celedon, Atmos is such a revolutionary

the tissue web are also accompanied

quality with exclusively virgin fiber

development in premium tissue pro-over the vacuum roll by two additio-

furnish. Atmos tissue machines,

duction that TAD machines will nonal fabrics. Underneath runs a dewa-

however, can also achieve such highlonger be a cost-effective option fortering fabric named AtmosFlex that

quality using mainly recovered paper

papermakers in future.

increases the dewatering effect of thefurnish. As an example, CMPC

vacuum, and on top is an open tensi-

Talagante uses more than 80% reco-

oning fabric named AtmosBelt thatvered paper furnish.
Contact

additionally presses water out of theweb. To reduce the viscosity of theConversion in less than eightwater, hot and humid air from thehours

Yankee hood exhaust is blown overthe fabrics, tissue web and vacuum

Atmos machines also have anotherroll. The structured fabric and gentle

advantage over TAD machines: thepressing prevent the paper fromfabrics can be arranged so that they

being squeezed and losing its

completely bypass the Atmos com-bulky character.

ponents. Then the same machine can

Tissue made by the Atmos process

be used for producing conventional

26 I 2008 I Voith Paper I twogether

Christian Münch
Tissuechristian.munch@voith.com

Thomas Scherb
Tissuethomas.scherb@voith.com

55

SERVICE

Customer benefit at a fixed priceWith pre-engineering to the Perfect Fit millPre-engineering is the basis of a well-founded project budget andensures that all sub-processes of paper production are optimallycoordinated with one another at an early stage. And that pays off:
• Lowest possible specific investment costs• Highest possible productivity and stability• Smooth project courses with the shortest
possible project running times
In the course of further increase in co-

the customer's goals is the decisivest efficiency in paper production, opti-

precondition for the Perfect Fit

mal coordination of all sub-processes

process. Ideally, the intensive coordi-

is gaining more and more significance.

nation between customer and Voith

The foundation stone for that is alrea-

takes place within the framework of ady laid an early stage of a large invest-

preliminary project in which the plan-

ment: with the preparation of thening documents, process layouts andfeasibility study, i.e., with the planningbuilding and mill plans are prepared.

of the entire system with paper machi-

These documents are the basis forne, auxiliary systems, building anddetermining the overall budget and theinfrastructure.

project schedule with high precision.

As process supplier, Voith contributes

With large projects, the pre-enginee-

more than 50% to the overall invest-

ring project typically lasts six to eight

ment volume. The influence is accor-

months. After that, the project has

dingly large. Consistent orientation to

been worked out to the extent that all

Fig. 2: Cost advantages through integrated engineering of all
sub-processes in shorter time.

Fig. 1: Increase of engineering reliability in shorter time.

Pre-engineering costs[million euros]

Overall investment budget[million euros]

FinalbudgetRisk

6-8monthsTraditional way of proceeding		

56

Voith

Pre-engineering
time [months]

6-8monthsTraditional way of proceeding		

Pre-engineering
time [months]

Voith

26 I 2008 I Voith Paper I twogether

SERVICEof construction wo
cutionrk
ExePreparation:• filler material• chem. WEP
electrification • coating/starch
Full erection

process pumps,
agitators• Stock preparation• Approach flow system(AWEP)• Paper machine• Secondary systems• Fabrics• Automation, QCS/DCS• SpeedSizer, Coater• Calender, RSM• Roll transp./pack.
• Services

hall ventilation(HVAC)

Pre-Engineering

crane installations, lifting
equipment
field instrumentation

field piping

vacuumsystemtanks,
vats,
towersdrives,MCC

Infrastructure

CustomerVoith PLP
Voith coreFig. 3: Typical supply limits with PLP projects.

sections are specified in detail andject costs. Along with that, the posi-

derably reduced. The project suc-the implementation can begin. In

tive influences on operating costs

cesses of various customers confirm

contrast to large projects in which,and consumption such as energy

the path taken. In the past threeaccording to the traditional way ofcosts and fresh water are becoming

years, Voith processed eight exten-

proceeding, a project was planned

more and more important. Especiallysive pre-engineering projects for new

without integration of the process

when Voith assumes responsibility forsystems in various regions and forsupplier, now considerable timesa-delivery and commissioning of thevarious paper grades. But along withvings result with simultaneously more

Process Line Package (PLP) including

pre-engineering projects for new ma-

precise budget planning (Fig. 1).

detailed planning, the advantages

chines, audits and pre-engineering

can be seen. The further overall pro-projects for larger rebuilds measures

On the basis of the extensive wealthject running time from the start ofon existing production lines are alsoof experience from numerous pro-project implementation to the begin-gaining significance. Risk minimiza-jects, the short coordination paths

ning of commercial paper production

tion and cost optimization throughbetween specialized departments

is shortened by up to two months.

Perfect Fit measures are the precon-and key personnel and the overall

Along with core processes, Voith

dition for lasting competitiveness.

planning of all sub-processes,

takes over with engineering, planningconsiderable cost advantages of theand delivery the responsibility for the

pre-engineering project result. For

sub-processes and sections all theVoith pre-engineering projects, theway to fulfillment of guarantees. With

maxim is to create customer benefit

this manner of proceeding, risks forat a fixed price and thus to make aninterfaces and unforeseen things on

essential contribution to lowering pro-the customer's side can be consi-

26 I 2008 I Voith Paper I twogether

Contact
Ingolf Cedra
Paper Machines Graphic
ingolf.cedra@voith.com

57

SERVICE

Inspiring – an environment far different from a traditional classroom setting.

Computer training programs allow a free choice of time and place

One EduCAT and an espresso, please!
The progress of computers is not to stop. They have been employedin paper machines for many years and are now increasingly used
for training purposes. Independence is the magic word. One could
learn to run a machine from just about anywhere – why not on abeach or in the mountains?

58

26 I 2008 I Voith Paper I twogether

SERVICE

Learning how to make paper was still

aspects simultaneously and also ma-

can be done around start-up. The

quite easy some decades ago.

ke mistakes safely.

new packages are called EduPACKs

A newcomer followed the advice of

In earlier times, the start-up of a new(Educational Package), featuring

senior employees and worked his

paper machine took several months.

interaction and control of success as

way through – “Learning by Doing“.

The machine supplier's experts

its most essential functions and using

trained the employees, and crucial

EduCAT (Educational Computer

In today's paper mills, such an ap-

issues were discussed directly at theAssisted Training), which is a cleverproach is hardly possible anymore.

machine. This method is good ande-learning software to combine

A modern paper machine can havefrequently used, but not always theknow-how transfer and testing oftens of thousands of single parts andbest.

learning progress.

control it. Learning and practising

Finding qualified people is not easy

Independent of time and place

every possible situation on the paper

everywhere, either. If skilled manpow-

machine is not feasible anymore. It iser or on-site training facilities are notControlling something complex is not

too expensive, too dangerous, too ti-

available, the customer is highly de-easy to learn from a handbook or

me-consuming – just to mention apendent on the supplier's know-how.

from some slides only. For the young-few reasons.

More and more greenfield projects

er generation growing up with com-are realized, and extremely toughputers, interactive learning is alreadytime schedules are set. Furthermore,routine. Everybody else, never fear!

some hundred computers alone toIndeed, there is a needdue to the very high degree ofNo special program skills or particular

When starting new paper machines

automation, experts are needed tocomputer requirements are needed.

or machine sections, several skills areoperate a paper machine.

required, in particular for process,E-learning has several notable advan-

control, and for papermaking. Nowa-

So, where to find these prodigies?

tages: Learning is not restricted bydays, only computer-based training

Since they are rare, Voith Paper offers

time or place. The modules can beoffers the possibility to learn all thesea wide range of training classes thattrained as many times as needed andOptimization
potentials

Machinehandling

Learn

Qualify

SafetyEduCAT
MachinecontrolTechnologicalknowledge

Technology

Test
Feedback

Components
Operation
Maintenance

Demands on training.

26 I 2008 I Voith Paper I twogether

Improve

Process
control

Certificate

Maintenance

Components of EduCAT.

59

SERVICE

are diverse, containing presentations,proof of successful training done withthe training modules can be updated

animations, text, videos and interac-

EduCAT.

and adapted to existing machine sec-

tive exercises.

tions.
Joachim Schipp, training developer atSince the customer needs are varied,

Voith Paper St. Pölten in Austria, is

EduCAT can also help solving tricky

several training packages are availa-

one of the brains behind EduCAT. Ac-questions. “Especially if the problem

ble. The keywords for EduPACK

cording to him, the goal is to provide

is of technological nature, a special

Basic are conventional training andcomplete, standardized computer-training module can be programmed

e-learning with EduCAT. EduPACK

based training. However, having one

for it“, the developer remarks.

Advanced offers an additional know-

module ready will not be enough.

ledge test for control of success.

Since every paper machine is unique,

A web portal for e-learning is planned

all modules are tailored according toto be realized in the near future.

the respective customer's needs.

Even if Joachim Schipp's job is to

Each trainee will have personal

Operators or technologists have otherdevelop e-learning, he believes that aaccess to the portal, where his/herneeds than maintenance people. But

perfect training does not consist ofadditional questions will immediately

no matter who is learning, there iscomputer-based learning only.

be answered by experts. On the

one subject they all have in common:“We would never just send the inter-

Internet, you can evaluate yoursafety.

active training CDs to the customer

learning success online at any time.

Blending is the answer

and then let him alone with them“,

And if necessary, go through it all

All the machine sections and func-

over once again ...

tions can be trained on the computer.

he emphasizes.

No matter, if a single part rebuild or a

The best alternative would be “blen-

If a fair amount of answers is correct,

complete new machine is concerned

ded training“ with EduPACK Advan-

the trainee can print a certificate as a

– everything is possible. Moreover,ced. Personal training on site, inter-

EduPACK

Functionality

EduPACK Advanced

Conventional

Basic

Advanced

Student

Presentations,handbook,
Training on site

EduPACK
Conventional+ interactivity

EduPACK Basic+ control ofsuccess

EduPACK Advanced(not projectoriented )Knowledge
100%

Conventional
training
Interactive training
with EduCAT

50%

Examination modewith EduCAT
E-learning Webportal ** planned

TimeInteractive training with EduPACK Advanced helps to deepen and evaluate what has been learned so far.
Thanks to repeatable training modules, the goal of 100% know-how is within reach!

60

26 I 2008 I Voith Paper I twogether

SERVICE

After learning you can test your knowledge.

The right answers are green, the wrong ones are red.

Customer Comment

active learning with the computer,used constantly. Deepening andfollowed by a face-to-face discussion,

repeating are the keys to effective

are the perfect combination.

learning!

Computer-assisted training is neverIndividual aspects should also be

unilateral. “The trainees' feedback istaken into account. People differ inhighly valued in order to enhance thelearning speed and previous know-

contents of training“, Joachim Schippledge. EduCAT helps to effectively

reminds us.

balance these differences.

The computer is a patient teacher and“Luckily, more and more customersof EduCAT training module. After accom-a just and reliable examiner. However,are getting very interested in the mostplishing the final test, Fors Training Coor-

the customer can perform additional

successful training methods. Fortuna-

dinator Theofil Krantz sent his enthusias-

tests to evaluate the training success.

tely, the selection of EduPACKs

tic remarks to Joachim Schipp.

E-learning can also be used as a test

available is big enough to fulfill“I must congratulate you and Voith ontool to measure the success of otheranyone's needs – no matter how

producing this material. I hope to seelearning methods.

large or small they are“, Joachim

more of this kind of material in the future!

Schipp remarks.

Overall it is very well done and once

Theofil Krantz
Training Coordinator
Stora Enso, Fors mill,
SwedenStora Enso Fors was one of the first users

Made for long-time use

again, I salute you for your good work.”

Unfortunately, the training does notalways have the highest priority andshrinks quite often to a minimum outof cost reasons. An e-learning tool ismade to last a long time and to be

26 I 2008 I Voith Paper I twogether

Contact
Charlotte Vogelsinger
Paper Machines
Board and Packaging
charlotte.vogelsinger@voith.com

61Service

RollCare: Ultrasonic testing of a roll cover.

Tailor-made mechanical roll service

RollCare, RollRep and RollUp Solutions lower costs
Rolls have a huge impact on machine efficiency and a mill’s profitability. By reducing unscheduled downtime due to roll problems andincreasing the roll change interval, a mill can significantly lower
the total cost of operation. To get the most effective and fastest
service, Voith has developed tailor-made mechanical roll service
modules, which are classified by three steps: RollCare, RollRepand RollUp Solutions.

62

26 I 2008 I Voith Paper I twogether

SERVICE

In fact, one could compare a roll to ahoses, flushing of shower headers

mal spray build-up, re-machining,

car and easily grasp the understan-and nozzles, replacement of lip seals

journal replacement, parts replace-ding between car and roll mainte-

and other wear items. Deflection

ment, shell ID honing.

nance. Like cars, rolls need periodic

compensated rolls require replace-

maintenance, occasional repairs,

ment of seals and testing for leaks.

and if necessary, upgrades to ensure

Generally speaking, a lot of small, yetmaximum reliability. Proper mainte-

important, details secure the runnabi-

Occasionally, high-tech products

nance always results in maximum

lity of your paper machine.

need a technology update, to ensure

performance.

RollUp Solutions

top performance. Voith can upgrade
RollRep

RollCareexisting rolls to provide improved
performance. For example, there may

Like cars, as rolls get older, the com-be some weaknesses that need to be

It is essential to clean and inspectponents corrode or wear out, and oc-

taken care of, or there are some pos-bearings, as well as inspect for any

casionally parts get damaged. Voith,sibilities to incorporate the latest en-wear or damages that may be deve-

as a manufacturer of rolls, has the ex-gineering concepts and improve theloping, such as cracks in journals or

perience and know-how to recom-

existing rolls. Through analysis of reli-in the shell. In addition to the bearing

mend the most appropriate repairs

ability records and design reviews,

assembly work, suction rolls requirethat will be cost effective yet provide

the weak areas of a roll can be preci-cleaning of the suction box, replace-reliable service. Some of the roll re-sely identified and design enhance-

ment of seal strips and air loading

pairs include: head fit sleeving, ther-ments can be implemented.

RollCare: Bearing inspection.

26 I 2008 I Voith Paper I twogether

RollRep: Thermal coating of a journal.

63

Service

RollUp Solutions:
InsiderJet installation.

Examples of Voith RollUp

Infobox: Overview of the benefits

Solutions:• Short bearing life can be costly.

RollCare:With Voith’s RollUp Solutions, every

Water may be getting into bearing

upgrade project is tailored for the

housing, or oil may be leaking out.

specific need, while ensuring to get

Machine speed has been increa-

the maximum results for a minimal in-sed, it may be necessary to convert

vestment. As a result, the ROI can befrom grease to oil lubrication.

very attractive.

Periodic maintenance & service• Suction rolls• Deflection compensated rolls• Press rolls, wire/felt rolls, reel spools, etc.
• Shell, head, journal inspection & NDT• Grinding, conventional and 3DG• Balancing, conventional and multi-plane

The solution: Bearing housing canbe re-designed for improved relia-

Voith has a dedicated team of engi-

bility.

neers and craftsmen specializing inpaper machine rolls. By partnering• A broken end deckle on a suction

with Voith, and effectively utilizing

roll can cause unscheduled down-these three modules, RollCare, Roll-

time.

Rep, and RollUp Solutions, reliability

The solution: An upgrade solution

will be improved, downtime reduced,

is available to strengthen the deck-machine availability obtained, andle mechanisms, and also give visual

better performance from the paper

feedback of the deckle position formachine rolls are aquired.

easy adjustment of vacuum zone
width.

• Suction roll’s seal strips may
be wearing out too fast; this may
cause frequent roll change intervals. Or seal strips have an imprecise position, this may provoke
web edge problems and sheet
breaks.

Contact
Jin KimRolls
jin.kim@voith.com

RollRep:
Repair & restore rolls to original design• Head fit repair• Any kind of Machining• Journal repair & replacement• Parts replacement• Shell ID honing

RollUp Solutions:
Upgrade old rolls with new engineering
concepts• Bearing housing improvement• Grease to oil conversion• End deckle redesign• Shower improvement•	InsiderJet installation(High pressure oscillating shower)•	SeaLencer installation(Noise-reducing sealings)• Seal strip upgrades

The solution: The shower headersand nozzles can be re-engineered
to improve the shell lubricationand enhance seal life, thus

Jochen Honold
Rolls
jochen.honold@voith.com

producing longer roll changeintervals.

64

26 I 2008 I Voith Paper I twogether

News from
Research andDevelopment

RESEARCH AND DEVELOPMENT

Tested: OnV FlocSpotter already successfully measures the formation at the headbox atVoith Paper Technology Center in Heidenheim, Germany.

Uniformity right from the start

OnV FlocSpotter measures formation
already on the forming wire
The latest image-processing innovation from Voith Paper Automation is the OnV FlocSpotter. This is the first system that enables theevaluation of the paper web uniformity already in the wire section.

66

26 I 2008 I Voith Paper I twogether

RESEARCH AND DEVELOPMENT

Formation is one of the mosta camera delivering high-resolution

comparison of the formation values

important quality parameters in thedata at a shutter speed of less thanfor different machine operational

papermaking process. It is decisive

10 microseconds had to be found forstatuses by operators. The programfor constant paper quality, since

the OnV FlocSpotter.

enables a visual representation offluctuations here have an effect on

the formation to be linked to thea number of other parameters.

For the sake of comparison: This isrespective operational status. There-

Accordingly, sufficient strength andfaster than an electrostatic flash

fore, the formation can be optimized

good printability are only obtaineddischarge. To ensure adequate expo-

in a targeted way during production.

with very uniform paper. Voith has

sure at such a short shutter speed,

now succeeded in developing a sen-

OnV FlocSpotter was equipped withsor that already measures the forma-a powerful LED illumination systemtion on the forming wire. This enables(Fig. 2). The OnV FlocSpotter

the papermaker to intervene in andcamera housing was also adapted to

Infobox: Formation

regulate the process at the earliest

the harsh conditions of the wirepossible stage: after sheet formation.

section. It was designed to prevent

In the production of multi-ply pro-accumulation of dirt particles.

Uniformity of paper web determined by
distribution and alignment of fibers in thepaper.

ducts, it also enables to determine
reliably the formation of individual

Thinking software

Contact

layers (Fig. 1). This is not possible
with the so far common formation

With the help of a software program,measurement at the reel.

the images taken by the OnV

Dr. Armin Bauer
Automation
armin.bauer@voith.com

FlocSpotter can be classified into
Faster than lightning

familiar formation categories

Rudolf Münch
Automation
rudolf.muench@voith.com(e.g. normal, coarse, and fine) and
To enable the formation to beevaluated. Together, these recorded

measured at speeds of more than

images form a “formation map” that

1,700 m/min (nearly 5,600 feet/min),can be used for rapid and simple

coarsewhite
pointsnormalfine

Fig. 1: On multi-ply cardboard machines,
measurements can be made on the different
headboxes.

26 I 2008 I Voith Paper I twogether

Fig. 2: Good exposure performance isachieved thanks to LED flash system.

Fig. 3: The formation map puts the current
measurement (red field) into a historicalperspective.

67

RESEARCH AND DEVELOPMENT

New concept in the dryer section

SafeTailing – reliable transfer even safer
A valuable development of ropeless transfer in the dryer section
is SafeTailing. Operation is safer and compressed air can be saved.

New transfer concept SafeTailing provides for more safety and compressed air savings in the dryer section.

68

26 I 2008 I Voith Paper I twogether

RESEARCH AND DEVELOPMENT

Pilot installation SafeTailing– dryer section with safety barrier.

SafeTailing in the TopDuoRun dryer section – tail cutting withpushbutton or with controller by means of vacuum sensor.

In TopDuoRun dryer sections, taildanger. In the future, tightened safety

without any problems. Activation oftransfer has been done “ropelessly“

regulations will hardly still allow

correct tail cutting is done in thefor almost 20 years. Only with thismanual intervention.

semi-automatic version by the opera-

technology was it possible to properly master the considerable speed in-

tor via a pushbutton. In the fully autoNew transfer concept

crease of the paper machines during

matic version, the tail is monitored via
vacuum break sensors. Interruptionstransfer as well. The tail is peeled off

SafeTailing is just the right thing.

are thus independently detected andthe cylinder by means of blast

The new transfer concept functions

eliminated by the system. In addition,

nozzles at the doctor and then fol-independently of the operator eventhe transfer blast pipes on thelows the dryer fabric or the stabilizer

with small interruptions and thus

doctors are only switched on if theroll to the next dryer cylinder. The tailoffers a high level of safety. At the

tail is also in this group. That saves

is thus transferred through the entire

same time, it is just as effective as

up to 50% with all transfers.

dryer section in a few seconds.

manual intervention. And in addition,
you save compressed air.

Nonetheless, it happens from time totime that the tail gets stuck on a

The pilot installation has beensuccessfully in operation for almost a

How SafeTailing works

cylinder during transfer and doesn't

year. Until now, it was semi-automaticwith pushbuttons. Lately, the system

go any further. In the past, the opera-

Blast pipes for cutting off tails are in-has been equipped with vacuum

tor had only two possibilities in thisstalled in the various dryer groups. If

break sensors for the tail.

case: Either to interrupt the entire

a interruption occurs during transfer,transfer process and start over fromthe cutting blast pipe located before

the beginning or to manually assist

the imperfection is activated. The tailwith the air blast hose so that the tailis briefly stopped by it. The transfer

is peeled off the dryer cylinder on theblast pipes are then switched on

second attempt. The second variant

again beginning with where the stop

is by far the more favoured, but

occurred and the tail continues

requires some skill and is not without

running through the dryer section

26 I 2008 I Voith Paper I twogether

ContactRoland Mayer
Paper Machines Graphic
roland.mayer@voith.com

69

RESEARCH AND DEVELOPMENT

Curtain coating with optimum coating color air removal

The AirEx AT-V lets the air out of coating colors
Curtain coating has been drawing more and more attention over thelast few years. It has become clear that perfect coating quality can
only be achieved with a completely deaerated coating color. At thePaper Technology Center (PTC) in Heidenheim (Germany), a new air
removal system for high-viscosity coating colors has been developed.
The AirEx AT-V achieves a residual air content of less than 0.1 vol.%.

The excellent quality of the curtain

the classic processes, the curtain

coating is primarily due to its outstan-coater requires more efficient air re-ding uniformity. However, nearly every

moval systems to achieve gas con-

air bubble in the coating color leads

tents of less than 0.1 vol.%. The state

to a defect in the paper coating.

of the art in specialty paper production, which is currently the main

If the air contents are compared be-application area for the curtain coater,

fore and after air removal for the clas-

is a vacuum deaerator used in thesic film and blade coating processes

chemical and food industries. For

and the curtain process (Fig. 1), thepigment coating colors with higher

higher air contents, even after air re-solids contents and viscosities, thesemoval, are found for the film and bla-

deaerators quickly reach their limits.

de processes. This is mainly due to

However, air removal is the key to thethe equalization elements, including

success of the curtain coater in thethe blade and the rod, under whichgraphic paper segment. For this rea-

air bubbles are squashed. Whereasson, Voith decided to take the deve-

cyclone deaerators with efficiencies

lopment of an air removal system forof 50% to 70% are fully adequate in

the specific requirements of the paper

5-12Offset

3-8

Blade

10-25

Roto

5-12
5-12

Film

3-8
2-5
<0.1

Curtain05

Air content before air removal

10
15
20
Air content [Vol%]25

30

Air content after air removal

Fig. 1: Comparison of air contents before and after air removal for blade, film, and curtain processes.

70

26 I 2008 I Voith Paper I twogether

RESEARCH AND DEVELOPMENT

industry “into its own hands.” The

key requirement of the air removal

AirEX AT-V was designed and alreadysystem. This problem was solved

drew the interest of a customer inthrough use of an automated cleaning

early 2007 during the development

device in combination with the smart

phase. The prototype of the air remo-

construction of the cascade ele-val system was tested at the PTC inments. Cleaning can be performed

the summer of 2007, and two units

by one person and requires approx.

were already successfully put into

70% less time than for other vacuum

operation for the customer indeaerators.

Coating color

Vacuum pump

December, resulting in a development
time of just twelve months!

Compact design

Advantages of the cascade

The compact design of the AirEx AT-V

principle

is important for rebuilds in tightspaces. With the multilayer curtain

A key feature of the AirEx AT-V is thecoater, a separate supply line with air

cascade principle, which, in compari-removal system is required for eachson with the vacuum deaerators fromcoating layer. This clearly illustrates

the competition, generates three

how important a space-saving air

times more surface for the same

removal installation is.

outer dimensions (Fig. 2). The coatingcolor supply to the air removal sy-

Visual evaluation impressively de-stem was optimized to distribute evenmonstrates the results of air removal:

high-viscosity coating colors com-

When applied to a glass plate andpletely uniformly in the system. This

viewed in transmitted light, the coa-

has a positive effect on the air remo-ting color has run out of air in theapplication unit are being made to theval result. Besides the air removal

AirEx AT-V (Fig. 3).

curtain coating process. Removal of

performance, the ability to be cleaned

Improvements extending beyond the

air from the coating color is a key ele-quickly during a grade change is apure mechanical development of thement in the generation of optimum

Fig. 2: The cascade principle of the AirEx
AT-V provides for three times the surface.

paper properties in the overall process. With the right components, thecurtain coater will become in the paper industry what it has always been
in other industries: the easiest andthus most efficient coating process.

Contact
Uwe Fröhlich
Paper Machines Graphic
uwe.froehlich@voith.com

Fig. 3: Glass plate test before …		

26 I 2008 I Voith Paper I twogether… and after air removal.

71

REPORT

Reflecting the exclusiveness – the interior of the retail store.

Büttenpapierfabrik Gmund opens first store in Munich

Premium paper with a handcrafted look
Last September Büttenpapierfabrik Gmund opened an exclusive retail store in Munich, allowing end
consumers to buy small quantities of the one-of-a-kind Gmund paper grades for the first time ever.
Especially popular are the paper grades that look like they are handmade.

The door opens, and Birgit Liebe

producing specialty papers since“We are not a museum,” states

beams. We are in “her” paper store,

1829 in Gmund am Tegernsee,

Florian Kohler, owner and CEO ofwhich is right behind the Bayerischer

Germany. Today the papers are deli-Büttenpapierfabrik Gmund. “Our old

Hof in Munich. This is not just any oldvered to more than 70 countries. With

paper machine runs at a low speed,

paper store. “We are specialized in

two paper machines, papers can be

but that’s exactly what we need to

exclusive premium paper, paper you

made in 60 different colors with up to

make our premium papers.”

can’t find anywhere else”, says store

six different basis weights. One of theThus arises paper with a handmade

manager Birgit Liebe.

machines, a Fourdrinier machine withcharacter. With 110 different calendera maximum width of 1.60 m (5.25rolls, diverse paper surfaces can be

The company behind the nice store

feet) and a length of 40 m (approx.

produced in Gmund. Whether it has awith the fascinating paper grades is

130 feet), has been in use since 1883

linen structure or a leather grain, each

Büttenpapierfabrik Gmund. Steeped

and is hence the oldest machine still

paper has its own feel. The secondin tradition, the paper mill has beenrunning in Europe.

paper machine is from Voith.

72

26 I 2008 I Voith Paper I twogether

REPORT

Originally built as the PM 407 in 1930,

son, she worked in the textile indus-

brown surface is decent and noble

the Voith machine was rebuilt intry. “The road from textiles to paper is– and without a red tinge, since this

1979/1980 and installed in Gmund.

not long at all. Both industries are all

could disturb the color impression of

It is one of the most modern premium

about the characteristics of materials,

the paper. They had been playing

paper machines of its kind in theabout beautiful and high-quality pro-with the idea of establishing a retailworld and enabled Gmund to add

ducts,” according to Liebe. She wasstore for a long time already.

larger formats and basis weights to

involved in the creation of the Gmund“We were contacted by a number of

its product range.

paper store in Munich right from theinterested parties who wanted tostart. July 2007 marked the beginningpurchase our paper in small quanti-of the store planning, which also

ties as private customers,” reports

involved a well-thought-out architec-

Florian Kohler.

tural design.

The small shop at the mill in Gmund

One-of-a-kind papers
The secret to Büttenpapierfabrik
Gmund’s success is the continuousat the Tegernsee first proved to be adevelopment of unique, high-quality

Exclusiveness already reflectedsuccess. Initially it was only open

paper grades. A special creation is ain the architecture

three afternoons a week. Now it ispaper with feathers incorporated intoexperiencing brisk business six days

it. It is like velvet to the touch, nearly

The store, designed by the Huchlers,

a week. The Gmund store in Munichlike a fabric. “The papers in the Natu-

an Austrian architect couple, exudes

was the next logical step in serving

rals series are the most popular herea cozy lounge atmosphere.

the many private customers andat the store,” claims Birgit Liebe.

The architects decided to use thepaper fans. Two-thirds of store visi-

They have high cotton contents andnoble, dark bog oak wood furniture

tors are private individuals who stockinclusions of plant-based raw materi-for two reasons:up on Gmund paper for high-quality

als such as straw, turf, bark, or“First, we are close to nature andwedding invitations, exquisite writingfeathers. Despite their felt marks andhave regional roots. Bog oak wood ispaper, or unique Christmas cards.

authentic deckled edges, they cancommon to the Bavarian and Alpine

The rest are commercial customers

even be used in inkjet printers.

regions,” according to Birgit Liebe.

wishing to design their company

Secondly, Kohler, Liebe, and theirstationery exclusively and individually.

“Paper fascinates me,” the shop

team spent a long time looking for a

The concept is catching on. Since es-

manager says with a smile. ”Thesuitable basis for the presentation of

tablishment of the store in September

quality one feels and the aura of athe papers. The structure of the wood2007 business has been outstanding,paper can transport many emotions.”

could not take away from the struc-and more stores are being planned

Before working as a paper salesper-

ture of the paper. The matt black-for major German cities.

Whether linen or leather structure, every paper feels different.

26 I 2008 I Voith Paper I twogether

Store Manager Birgit Liebe offers unique papers.

73

NEWS

Dr. Hermut Kormann was bid farewell on the occasionof a customer event with an impressive ambienceon the Voith premises in Heidenheim, Germany.

Management trio – Three generations of Chief Executive Officers:
Dr. Hermut Kormann (center) with his predecessor Dr. Michael Rogowski(left) and the new Voith CEO Dr. Hubert Lienhard.

Farewell of Dr. Hermut Kormann, Chairman of the Board of Voith AG

Change at the top of Voith AG
Effective at the end of March 2008, Dr. Hermut Kormann has, at the age of 66, stepped down from his
position as President and Chief Executive Officer of Voith AG. Precedingly, the Supervisory Board had
approved the proposal submitted by the Shareholders' Committee and unanimously appointed Dr. Hubert
Lienhard, member of the Board of Management of Voith AG and Chief Executive of Voith Siemens Hydro
Power Generation, as his successor.
During his tenure as CEO of Voith AG,

business from 1.2 billion euros to today'srisk management. Dr. Lienhard is a

Dr. Kormann has made a name for him-

volume of 5 billion euros. Dr. Lienhard

member of both the Administrative

self primarily as a consistent and capa-

began his service to Voith AG in 2001,

Board of Sulzer AG and the Supervisory

ble corporate strategist. In his position

when he came from ABB and was ap-

Board of SGL Carbon AG. He also ser-as Chief Financial Officer, he, together

pointed to the Board of Management. A

ves as India Liaison Officer for the Asiawith Dr. Michael Rogowski, today theyear later, he assumed the role of Chief

Pacific Committee of the Association ofchairman of the Voith supervisory board, Executive of Voith Siemens Hydro Power

German Industry, and is a member of

was instrumental in steering Voith safely

Generation GmbH & Co. KG, while also

the German-Indian Advisory Group.

through a division of ownership in theshouldering additional functional respon-

1990s and subsequently driving Groupsibilities for strategic procurement and“His breadth and depth of industry
experience, his commitment to theconcept of the 'family-owned company'and his history of successful service
among his peers make Dr. Lienhard aworthy choice as President and Chief
Executive Officer,“ Dr. Rogowski told.
Since April 1, 2008, Dr. Lienhard isleading the Voith Group in this new capacity. “I am pleased at the trust placedin me by the shareholders, the Share-

Dr. Hubert Lienhard
has been the new CEO
of Voith AG since
1st April 2008.

holders' Committee, the Supervisory
Board and the Advisory Council,“Dr. Lienhard said. “I will devote all myenergies to sustaining and shaping the
success story that is Voith.“74

26 I 2008 I Voith Paper I twogether

News

Ming Ming Liu, President Voith Paper China Co.,
Ltd. and Jialin Wu, Chairman of the Board of
Yueyang Forest & Paper Group, after thecontract signing.

The largest Vorecon (33 MW) so far
on the test bench in Crailsheim.

Contract signing for the Longkaikou hydropower station in China.

Voith Paper

Voith Turbo

Voith Siemens Hydro

Large order
received from
Yueyang Paper

Energy for new
coal-burning power
plant in South Africa

Generators forhydro power plantat the Yangtze

Yueyang Paper, one of China’s ten

Voith Turbo has received a large order

Voith Siemens Hydro Shanghai will

largest paper and board producer,from the South African electric power

supply five 400 MVA generators forhas given Voith Paper the order tocompany Eskom for the delivery of

the Longkaikou hydro power stationdeliver the PM 9 and PM 10 as part of18 Vorecon. The adjustable planetaryin the Chinese province of Yunnan.

the 400,000 tons/year project.

gearings will be used in a new coal-

The volume of the contract awarded

burning power plant. The nationalby operator Langcangjiang Hydro“We have full confidence to accom-

energy supplier is investing in the firstamounts to more than 65 million

plish the project with Voith Paper as

new coal-burning power plant to be

euros. The generators will be

our major partner“, stated Jialin Wu,

built in Africa in 20 years because of

manufactured in the workshops ofChairman of the Board of Yueyangrising energy demand. “Medupi” will

Voith Siemens Hydro in Shanghai.

Forest & Paper Group.

be larger than any power plant inGermany with 4,749 MW of power.

Upon completion, Longkaikou hydropower station, located on the upper

The new machines, PM 9 and PM 10,
are identical and will be built accor-

Voith Turbo will deliver the 18 Vore-reaches of the Yangtze River in theding to the one platform concept andcon with 17 MW power each between

southwest of China, will have a total

feature state-of-the-art technology.

2009 and 2011. The machines will be

installed capacity of 1,800 MW andWith a wire width of 5.85 m and withcustom-made. However, there will be

generate 7.8 million MWh of electrici-

the design speed of 1,400 m/min,no changes to Vorecon’s operating

ty on an average per year.

both machines will produce 200,000

mode, after all the gearing is being

tons of printing paper per year.

used successfully worldwide with

Besides Longkaikou, Voith Siemens

99.97% reliability (calculated based

Hydro is currently also supplying

The start-ups are scheduled in theon machines in operation) – forequipment for two more hydro power

third quarter of 2009.

example, in compressors, pumps

stations of Langcangjiang Hydro:

and blowers in power plants or also

Xiaowan and Nuozhadu.

in the oil and gas industry as well as
the petrochemical industry.

26 I 2008 I Voith Paper I twogether

75

News magazine for theinternational clientele,
partners and friends ofVoith Paper“twogether” is published twice annuallyin German, English, Chinese, Russian and­Finnish. Contributions by independent
authors do not necessarily reflect the opinion of the publisher. Please address all correspondence to the editor.
Published by:Voith Paper Holding GmbH & Co. KG
Editor:Stefanie Weber, Corporate Marketing
Voith Paper Holding GmbH & Co. KG
St. Poeltener Straße 43
89522 Heidenheim, Germany
twogether.voithpaper@voith.com
http://www.voithpaper.de
Design, layout and typesetting:Beate Hornischer
Corporate Marketing
Voith Paper Holding GmbH & Co. KG

Issue 26, June 2008

Copyright 2/2008: No part of thispublication may be reproduced or copied
by any means whatsoever without theexpress permission of the editor.

Printed on chlorine-free bleached paper manufactured with Voith Paper machinery.

Voith Paper