twogether
Paper Technology Journal

First IEM starts up at Perlen Papier AG I New plants in India:

32

Tamil Nadu PM 3 and Dandeli PM 6 I Energy gain from sludge

32 I 2011 I Voith Paper I twogether

2

EDITORIAL

News magazine for the international
clientele, partners and friends ofVoith Paper.

“twogether” is published twice
annually in German, English, Chineseand Russian. Contributions by
independent authors do notnecessarily reflect the opinion of
the publisher. Please address allcorrespondence to the editor.

2

Dr. Hans-Peter Sollinger, Member of theVoith GmbH Management Board andCEO of Voith Paper.

32 I 2011 I Voith Paper I twogether

EDITORIAL

Dear customers, dear readers,With the PM 7 at Perlen Papier AG, the first Integrated EcoMill has gone into operation. Our
expectations for this concept, and of course those of our customers, have been met and evenexceeded: since startup, the PM 7 has produced paper qualities of the highest level and with
noticeably reduced energy and water consumption. Some of the technical highlights of the new
production line are presented starting on page 12.
This issue’s “New technologies” section features a whole series of innovations. One example is
SynStron, a yarn developed by Voith Paper that gives the customer a 30% longer service life forthe dryer fabric. With the Voith LSC TecoSens sensor, fiber weight and moisture in tissue
production can now be measured without radioactive beta rays. A big success not only for worksafety in paper mills, but also with regard to operating costs (p. 46).
The big advantage of the new spreader roll from Voith Paper is continuous sheet adjustment.
The spreading effect can thus be adapted to any operating situation. As coating specialists, we
can of course provide this roll with special surface qualities to match each application (p. 50).
The “Focus” topic of this issue is “Wastewater, sludge, rejects.” Thanks to our new CTC
technology, the potential of paper sludge can now be utilized, and value creation in this area canbe increased. As a significant part of the Integrated EcoMill, paper sludge can be converted into
valuable mineral products and thermal energy by means of CTC (controlled thermal conversion).
This is an important contribution in reducing sludge, CO2 and energy consumption (p. 60).
Finally, take a look at pages 74 and 75 during your next coffee break. Here we’ve collected somematerial for you that is entertaining and worth knowing.

Enjoy your reading!

On behalf of the Voith Paper Team

32 I 2011 I Voith Paper I twogether

3

CONTENT

Cover topic

twogether
Paper Technology Journal

First IEM starts up at Perlen Papier AG I New plants in India:

32

Tamil Nadu PM 3 and Dandeli PM 6 I Energy gain from sludge

32 I 2011 I Voith Paper I twogether

First IEM starts up at Perlen Papier AG
Achieving a lot with a little energy

6“Overall energy balance clearly improved”
In conversation: Jörg Michel on the new PM 7

11

33% less energy thanks to LowEnergyFlotation

12

From preparation to the packed roll

13

Bundled expertise supports quick startup

14

ClassicPlus has the highest flexibility

15

New plants

2

On the cover pictureWith the startup of the PM 7 at Perlen
Papier AG, the first Integrated EcoMill went
into operation. From the beginning, the

New PM 3 provides increasein capacity at TNPL
Quality paper for India and the world

18

A new age of paper production
Dandeli PM 6 successfully started up

21

entire production line has consumed fewer
resources, is highly cost-effective andproduces paper of the highest quality.

4

Rebuilds
Study: 70% worldwide waste energy
ScreenFit Compass 2011 analyzes
screening systems

24

Stability is key
C-bar M screen basket completes
screening portfolio

27

Getting winders moving again
Complex rebuilding projects in three to seven days

28

New PM 3 provides increase in capacity at TNPL.

18

32 I 2011 I Voith Paper I twogether

CONTENT

Products on site
Trouble-free pulper detrashing operation
IntensaMaXX reliably removes contaminants

31

High-frequency shaking preserves resources
DuoShake and CarboForm in combination

34

Rondo Ganahl saves costs with new QCS
Tailored automation package enhances
process stability

36

Fewer breaks thanks to integrated
drive solutions
Synergy between mechanical engineeringand automation

39

Evolution improves dewatering in the press
Breakthrough with tissue fabrics

42

Making the invisible visible
NipVision – for nip measurements while the
PM is running

56

Spotlight:
wastewater, sludge, rejects
Greater added value thanks to CTC technology

60

Converting sludge into minerals and energy“The value of the sludge is in the minerals”
In conversation: the co-developer of CTC

63

Simple reactor concept, high performance
New development in anaerobic wastewater
treatment

64

Service

New technologies
More effective dryer fabrics thanks to SynStron
A new class of polyester monofilaments

44

Service contracts ease load for papermakers
From service provider to integrated service partner

Sensor measures fiber weight and moisture
without radioactive source
Voith LSC TecoSens for tissue manufacture

46

Forum

Market leader further improved
DuoFormer D II impresses thanks to extended
application limits

48

Spreader roll reinvented
CarboStretch can do much more

67

Less energy, water and waste worldwide
Sustainability in practice at Voith Paper

70

More hydropower for China
Two new orders for Voith Hydro

72

50

Saving energy with LEDs
Voith Industrial Services lets the light shine

72

Increased service life through longer
grinding intervals and high reliability
New rubber roll covers for the press section

53

Strong teeth for connecting and positioning
Precision with Hirth couplings from Voith Turbo73

For the 5-minute break74

Rondo Ganahl saves costs with new QCS.

36

On track to maximize waste potential.

58

32 I 2011 I Voith Paper I twogether

5COVER STORY

Achieving a lot with a little energy

First IEM starts up at
Perlen Papier AG
Economical, environmentally friendly, regionally adapted – these are the essential
criteria that distinguish a Voith Paper Integrated EcoMill (IEM). The IEM concept was
implemented with the PM 7 at Perlen Papier AG, with the resulting resource consumption
there for newsprint being well below the average. From the beginning, 5% less electricalenergy per metric ton of paper has been consumed than with the PM 5, which was repeatedly optimized and is now shut down. This not only protects the environment but also
pays off economically for the Swiss paper manufacturer.

6

32 I 2011 I Voith Paper I twogether

COVER STORY

Perlen PM 7 – anIntegrated EcoMill
in numbers
360,000 t/year
Production capacity

40-52 g/m2
Basis weight10.45 mWire width

2,000 m/min
Design speed

1,900 m/min
Maximum production speed

1,662 m/min
Start-up speed (world record)

30%
Lower fresh water consumption
across the entire paper millCompared with the PM 5,
optimized to its maximum
and now shut down:

5%
Lower electrical energy use*

10%
Lower thermal energy use*

50%
Fewer additive costs** All results per metric ton.

Fig. 1: Perlen PM 7, Switzerland.
32 I 2011 I Voith Paper I twogether

7

COVER STORY

From the very beginning, thegood to very good marketable

PM 7 looked set to be a record

quality.”breaker. The production line clearly
demonstrates the benefits of theAccording to Michel, this is due to

IEM concept in real life. As a

optimally integrated processes fromcomplete system provider, Voith

dewatering (DuoFormer) and thedelivered wastewater treatment,press section (DuoCentri NipcoFlex

stock preparation, the paperwith three nips and a fourth press)

machine, winder, roll transport andto the dryer section (in which 31

roll packing systems, as well as thedryer cylinders are used in six dryer

entire automation. In terms of thegroups). In direct comparison to theprocess line package, Voith Paper

shut-down PM 5, which was

was also responsible for delivery,

technically updated throughoverall assembly, startup andcontinuous further development,

optimization of the entire production

even right after startup the new PM 7

line. Resource preservation was at

was consuming 5% less electricalthe heart of the overall conceptenergy per metric ton of paper

Voith expanded the existing ALPA 1

developed in close collaboration

produced. Even in terms of thermal

recovered paper recycling plant by

with Perlen Papier AG, Switzerland,

energy, PM 7 is better compared toadding the ALPA 2 to its overall concept.

in which all processes are holistically

PM 5. The goal is to achieve an

Due to the integrated processes in thecoordinated with one another.

energy requirement that is lower byrecovered paper preparation system,

about 10%. In addition, the additive

not only is the yield in stock preparation

The PM 7 already consumes

costs for binding agents, starch,increased, but Perlen Papier AG also

5% less electrical energy

talcum and dyes on the PM 7 havesaves 7 GWh of energy annually.

been nearly cut in half, particularly

The latest flotation technology,

due to the modern press section.

LowEnergyFlotation (LEF), plays a

As Jörg Michel of Perlen Papiersignificant role in this. For the first

AG’s management observes (seeinterview p. 11), “Almost from the

TwinDrum and LowEnergy-

time, Voith equipped a new system withvery start, we took a big leap forward

Flotation ideally prepare stock

this technology yielding a sensational
result: Inks are efficiently removed andwith the PM 7’s running time
efficiency. And even more important:

Recycling of recovered paper is an

the energy used for this at Perlen is

From the beginning, we produced

important topic at Perlen Papier AG.

reduced by more than 30%.

Fig. 3
VariTop winder

8

VariTop winder

Sirius reeler

EcoSoft Delta calender

32 I 2011 I Voith Paper I twogether

COVER STORY

a reduced requirement for additives.

stages and three secondary

With a pulping consistency of 25 toclarification tanks. They ensure that

28%, outstanding ink removal isbiologically purified water can beachieved, among other benefits,discharged into the fish-abundant

due to the integrated displacer

Reuss River, which has its source

located in the pulping section of thein the Saint-Gotthard Massif in

TwinDrum.

the Swiss Alps. Therefore, thecompany meets the highest

30% less fresh water is needed

ecological requirements of the
Swiss environmental authorities.

Consumption of fresh water acrossFig. 2: The TwinDrum lowers
additive consumption at Perlen.

the entire paper mill was lowered byPerlen Papier AG gets its fresh water

one-third. This is a result of waterfrom its own well, where the village

management in all areas, fromof Perlen also gets its drinking water.

recovered paper preparation to theThus, in further processing of thetwo paper machines (the existingwater, there is a strict separation of

The recovered paper used comes

PM 4 and the new PM 7) and thedrinking water and industrial water.

mainly from household material

wastewater treatment system.

Perlen Papier AG uses around 50% of
the fresh water as cooling water andcollected in Germany and Switzerland.
The bundles of recovered paper fromThe latter includes purification ofdischarges it back into natural

Switzerland are typically packed withthe water circulation system andcirculation uncontaminated.

various cords. The ALPA 2 not only

reject treatment, for which Voith has

removes the cords from the recovered

developed and implemented a new

IEM adapted to location andpaper but also de-wires bales weighing

concept for machine and process

customer requirements

several tons, in fully automatedtechnology. During ongoing operation

fashion, and feeds the loose recoveredof the paper mill, the capacity ofStarting from the initial requirements,

paper into the TwinDrum. This

the clarification facility was doubled

the Perlen PM 7 was designed so that

TwinDrum with a capacity of about

to 1,000 m³/h of wastewater andit would not only meet the customer’s

1,500 t/day continuously supplies

50 t/day of COD load. Two moving

quality expectations but also makeboth stock preparation lines. Its

bed biological reactors (MBBR) areuse of existing conditions and beinnovative pulping concept combines

used as high-load biological stages

capable of being embedded in thethe gentle slushing of fibers withfollowed by two low-load biologicalexisting infrastructure. In addition,

TopDuoRun dryer section

32 I 2011 I Voith Paper I twogether

DuoCentri NipcoFlex press

DuoFormer TQv

9COVER STORY

Fig. 4: The center winding principle of the two VariTop winders ensures good core-winding tightness, an important quality parameterfor processing in fast-running printing machines.

through integration of all essential

reworked. Thus 35,000 m3 of grossthe paper quality positively,” says

processes, consumption of resources

floor area were saved. Since theMichel, who is responsible for thewas reduced to a minimum.

building was kept as small as

areas of production and technology.

possible, costs could be reduced.

In addition, Voith integrated a special
solution into its concept in the

Important parameters were definedand established in the preliminary

In addition, the machine width

packing system area. Rolls that are

project phase. Printing tests andand speed were adapted to thedelivered to Swiss customers nosurveys of Perlen Papier AG’scustomer requirements, and thelonger have extra packing at thecustomers gave an exact overview

anticipated need for electricity,

front in a separate process step.

of the quality requirements the newsteam, water and chemicals wasThis saves packing material, time

paper machine had to meet. Highdetermined. Subsequently, theand is in equal measure an ecologicalconsistency, the best running

project team optimally assembled

and economic advantage.

characteristics and printability of

the corresponding system

the paper were the main concerns.

components and carried out theAfter an exemplary startup, thefirst calculations of efficiency.

Perlen PM 7 began production in
September 2010 and since then has

Before drawing up the first layout for
the new PM 7, the project team

Quality improvement using the

been running to everyone’s complete

determined its optimal location, on

center winding principle

satisfaction. In close collaboration,
Perlen Papier AG and Voith Paper

the company’s premises. Advantage
was gained from the hillside location,

According to Jörg Michel, theimplemented a system that adheres

and the machine hall was built so

configuration of the press section

to the strictest environmental criteria,that one side now has ground-level

and the winder with the center

works efficiently and – with Swiss

access to the PM floor and the otherwinding principle significantly

perfection – produces paper at theside has access to the machine pit.

contributed to improving the paper’s

highest quality level.

Even the dimensions of the building

quality. “Our customers madewhere the PM 7 is housed wereseveral test runs and always judged

10

32 I 2011 I Voith Paper I twogether

COVER STORY

In conversation: Jörg Michel on the new PM 7 at Perlen Papier AG“Overall energy balance clearly improved”
Jörg Michel, certified chemist and member of management at Perlen Papier AG, says the paper
market in Europe is very competitive. Those who want to hold their ground in the area of newsprint
paper production over the medium and long term need efficient, economical systems.
Mr. Michel, why has Perlen Papier AG

Why did your company decide in

What are your experiences currently

decided on a new production line?

favor of a system from Voith Paper?

with the PM 7?

We are, of course, constantly

Already in the preliminary project

The PM 7 started up according towatching market developments. In

phase, we could see that theschedule at the beginning of

our estimation, even with falling

Voith team was well ahead of its

September 2010 and since January

demand for newsprint in the markets

competitors in the project of2011 has taken a big leap forwardof Switzerland, Germany, Italy andrecovered paper preparation and inregarding running time efficiency. For

France, which we primarily supply

de-inking technology. In addition,

2011, we are planning 300,000 metricwithin a radius of 600 kilometers,from our collaboration with Voith wetons of paper, and soon we are

only those paper manufacturers

expected a top-level performance

expecting a final capacity of 360,000

that can keep up their margins canwith regard to deadlines, costs,

tons. From the beginning, the PM 7

survive. The size and capacity of a

product quality and reliability. All

produced good to very goodsystem are of significance here. In

our expectations were fully met.

marketable qualities. We are thus

our industry, those who don’t invest

meeting the highest customer

die a slow death.

requirements for newsprint papers.
Perlen Papier places a lot ofFig. 1: Jörg Michel, member of Perlen Papier AG management (left), and Johannes Rimpf,
Project Manager at Voith Paper (right), look back on the successful course of the project.

importance on environmental
management. How does the
PM 7 contribute to this?
Due to closed water cycles, weconsume about one-third less water
throughout the paper mill with thewater management system
implemented by Voith Paper. In thecase of thermal energy, we willcertainly reach our goal of 10%
lower energy use. The plant willclearly improve its overall energybalance, since we are massively
increasing the amount of recovered
paper used as a raw material.
Preparation of recovered paper
requires noticeably less energy than
preparing paper pulp from wood.

11

COVER STORY: HIGHLIGHT FIBER & ENVIRONMENTAL SOLUTIONSEnergy requirement in various ﬂotation systems
Energy requirement [kW]2,000

* As of March 2011 at Perlen

1,600
1,200
800
400
0

Fig. 1: The new LowEnergyFlotation (LEF) at
Perlen.

Fig. 2: High-efficiency LEF
pump.

Standard ﬂotation

LowEnergyFlotation LowEnergyFlotation
with standard pumps with high-efﬁciency
pumps*

Fig. 3: Reduced energy requirement for flotation
with the new LEF.

33% less energy thanks to LowEnergyFlotation
In the flotation stage of thesignificantly lowered. Generally,

high-efficiency pumps developed

de-inking system for the PM 7 atflotation is one of the most energy-

specifically for LEF.

Perlen, flow characteristics andintensive areas of stock preparation

mechanical components arefor newsprint, using about 20%

Due to better flow characteristics,

perfectly coordinated with oneof total energy.

LEF reduces energy consumption

another. The key to success ison all levels of the flotation.

LowEnergyFlotation (LEF); ThroughThe primary aim of the researchThis includes transportation of

consistent further development ofand development work on

the de-inking suspension, feed-in

the fluid dynamics, the energy

LEF was to clearly reduce theof air to the system, air bubble

consumption in this flotationenergy requirement for flotation

separation, as well as skimming

stage was immediately reduced

while maintaining outstanding

off and conveying of the flotationby 33%. Currently it is 18 kWh/t –flotation results. This was achieved

foam. The DIP plant of thewith the full potential of the LEF

through a modification of thePM 7 is the first new systemsystem not even utilized yet. For

injector technology, optimization

to use LEF.

Perlen, the operating costs of theof injector and EcoCell

700 t/day plant are alreadyhydrodynamics and use of

Scope of supply:Complete de-inking system, from planning (pre-, basic and detailengineering), delivery and installation to startup

New development of nutrient storage and dosing, additional MBBR high-load reactor
and rebuild of existing high-load reactor with new ventilation system

Feeding system for recovered paper with automatic de-wiring,
pulping by means of TwinDrum

New sedimentation, rebuild of existing sedimentation as secondary clarification tank,gradual expansion of clarification system during ongoing production

Screening systems with MultiSorters and C-bar screen baskets,
LowEnergyFlotation

Water, sludge and reject subsystems, sludge dewatering including transport system

Thune Bagless disc filters and screw presses, dispersing systemwith HC bleaching
Comprehensive services beginning with pilot plant tests andextending to final system optimization

12

32 I 2011 I Voith Paper I twogether

COVER STORY: HIGHLIGHT AUTOMATION

Fig. 1: Field instruments in use.

Fig. 2: Constant monitoring from the control room.

Fig. 3: The Voith LSC
Scanner checks paper
quality.

From preparation to the packed roll
Perlen Papier AG decided in favor ofarmatures and various sensors

The project manager for the area ofa complete, consistent automationsuch as pressure, flow or

automation technology at Perlen

package for the entire production

consistency transmitters. In addition,

Papier AG, Michael Nageler, is happy

line, from preparation of recovered

Voith also assumed responsibility

about the successful startup: “Thepaper to the packed roll. The

for electrification, the multi-motor

entire delivery of the automation

automation concept was developed

drives, individual inverters andpackage really made the work flowin collaboration between Perlen

robots at the packing system.

easy. Problems onsite were tackled

Papier AG and Voith Paper and was

For the customer this meant a

directly by the Voith specialists andtailored exactly to the needs of thedelivery from one source, fromcompetently solved. We are very

customer.

basic engineering to system

satisfied with the entire package andoptimization. Collaboration between

the handling of the project.”Along with the machine control andthe mechanical engineers, process

distributed control technology, thisengineers and fabric experts frompackage includes – among others

Voith Paper ensured the– all field instruments used in thetechnological components were

process. These consist of valves,

ideally coordinated with one another.

Scope of supply:
Machine control (MCS) and distributed control system (DCS) for the
ALPA 2 recovered paper recycling plant and PM

Quality control system with scanner, CD and MD profile controls

Expansion of existing DCS for wastewater purification system andsludge presses

Web inspection system and web break detection system

System engineering (basic and detail)Information system with trending and reporting

Field instruments for ALPA 2, the approach flow system and paper
machineComplete electronic equipment including 12 kV level such as transformers,
multi-motor drive, MCCs and frequency inverters

Controls and drive solutions for the winder and packing system

Robots for the packing system, adjustable machine drives for the PM and winder,
ITV camera technology

32 I 2011 I Voith Paper I twogether

13

COVER STORY: HIGHLIGHT FABRIC & ROLL SYSTEMS

Fig. 1: Wire section and pick-up felt.

Fig. 2: SkyLine doctor blades on
the way to installation.

Fig. 3: Various roll coatings and covers in thefinishing area.

Bundled expertise supports quick startup
With a start up speed ofto the future PM 7 with regard tosource all roll covers from Voith but

1,662 m/min, the PM 7 had thequality and running characteristics.

also the complete roll service for the

fastest ever startup of a paper

The actual startup onsite was

PM 7 over the next three years.

machine. Part of this success wastherefore handled very quickly

due to the optimal interplay ofand smoothly. In addition, thefabrics, roll covers and doctors

first paper produced directly afterthat was established in pre-testing.

startup in September 2010 met theThis took place at the Paper

customer’s requirements.

Technology Center (PTC) in
Heidenheim, Germany.

Perlen Papier AG specified thefabrics, roll covers and doctors

The mixture of materials used inused according to the quality

Perlen was replicated for extensive

standards for its machine.

testing at the PTC. This was well

Additionally, within the framework

worth it; Already during testing theof total roll management, thefabrics could be precisely adapted

paper mill decided not only to

Scope of supply:
Top and bottom wires in the former

Polyurethane roll cover for the suction press rollPress felts for all 4 presses

Thermal roll coating of the top roll in the 4th press and the center roll

Dryer fabrics for all dryer groups

Roll coatings and covers on various wire, felt and paper guide rolls

Cleaning and removal doctors on center rolls and the top roll in the
4th press

14

32 I 2011 I Voith Paper I twogether

COVER STORY: HIGHLIGHT PAPER MACHINES

Fig. 1: Roll transport to storage.

Fig. 2: Mobile-mounted winding head of theClassicPlus roll packing machine.

Fig. 3: Outer cover robots at work.

ClassicPlus has the highest flexibility
For packing the finished rolls of

Currently, the ClassicPlus isoutside covers and for attaching thethe PM 7, Perlen Papier AG decided

designed for 70 rolls per hourshipping labels. Only one employee

in favor of the newly developed

from the PM 7; in the future, theis required for operation of theClassicPlus roll packing machinerolls of the Perlen PM 4 will also be

packing machine.

with an extensive roll transport

packed in it. Its modular concept

system.

allows an increase in capacity, with

Full packs (circumference and ends)

additional components, to 130 rolls

for international shipping and also

The ClassicPlus uses the principle

per hour. Another advantage of thean edge-aligned circumferentialof parallel packing with a water-

ClassicPlus is that it requires only

pack for customers within

proof kraft paper. For this, the

50% of the installation space of the

Switzerland are possible with theroll is wound with parallel layers,classic packing system, e.g., withsystem. Packing material can thusa mobile winding head being

four fixed unwinders.

be saved, providing an economical

applied several times depending

and ecological advantage for Perlenon the roll width. For mutual

The system was designed to besealing, the layers are glued to

fully automatic and uses industrial

one another.

robots for attaching the inside andPapier AG.

Scope of supply:
Approach flow system with Hydromix, HCL5 cleaner system with
EcoMizer, MSA MultiScreen, bleeding with the VoithVac

TopDuoRun dryer section allows energy-efficient drying with the best runningcharacteristics

PowerTube turbine for energy recovery, Save-All disk filters,
CompactPulper for broke pulping

2 EcoSoft Delta calenders provide for the best paper surfaces, Sirius roll-up system
for maximum roll diameter of 4,000 mm

DuoFormer TQv with ModuleJet headbox for first-class formation

2 VariTop winders for production of large rolls with various core materials

DuoCentri NipcoFlex press with 4th press ensures the highest dry
content

ClassicPlus packing system uses the principle of parallel packing and due to its
modular concept gives the highest flexibility in roll packing

32 I 2011 I Voith Paper I twogether

15

COVER STORY

16

COVER STORY

Perlen Papier AG is situated in the idyllic Swisslandscape. With the PM 7, an Integrated EcoMill is inoperation here that meets the highest requirementswith regard to cost-effectiveness and environmental
friendliness. Integration of all partial processes into theoverall concept pays off: The PM 7 consumes fewer
resources than conventional systems. The yield of stock
preparation was increased and consumption of additives,energy and fresh water was substantially lowered. The
Integrated EcoMill in Perlen – a sustainable alternativein which economy and ecology go hand in hand.

Fig. 1: Perlen PM 7 – an Integrated EcoMill.

32 I 2011 I Voith Paper I twogether

17

NEW PLANTS

Quality paper for India and the world

New PM 3 provides increase in capacity at TNPL
Tamilnadu Newsprint and Papers Limited (TNPL), one of the leading companies in integrated pulp andpaper manufacturing, recently started up its new PM 3 from Voith Paper. With a wire width of 6,100 mm
and a capacity of 155,000 tons/year, the paper machine will expand the annual production capacity of
TNPL to 400,000 tons of top-quality writing and printing paper.
Growth is nothing new for thewell as environmental considerations,

Using bagasse requires

dynamic TNPL. Since the start

which will help the company achieve

experience and know-how

of operations in the 1980s, with aan international quality level.

production capacity of 90,000 tons/

Through this investment the company

year, the paper mill has gone throughAlong with integration of the pulp

has positioned itself as the largest

numerous expansions and upgrades.

mill, which mainly processes bagasse

paper mill worldwide that works from

With the PM 3, TNPL is currently in

as a raw material, installation of a>>> bagasse. Beside short fibers,

the final phase of a big investment

new production line was one of theabout one million tons of bagasse areprogram, which envisions an increase

most important investments of

to be processed annually. However, thein capacity for high-quality writing

the recent past. The new Voithuse of bagasse raises a whole series ofand printing paper from 245,000

paper machine with a wire width ofcomplex questions for the paper

to 400,000 tons/year. At the same

6,100 mm and a design speed of

manufacturer and the supplier of thetime, efficiency measures are being

1,200 m/min is built for a production

paper machine. Due to the dewatering

implemented both in production as

capacity of 155,000 tons/year.

characteristics of bagasse, the drying
process lasts 40-60% longer than in
the case of conventional production
with wood pulp, i.e., a significantly
longer dewatering section has to beinstalled. In addition, there is a higher
shrinkage rate. In order to compensate
for this, the machine has to be
designed to be wider. Furthermore,bagasse tends to be more adhesive,
which poses a challenge for the press
section. Due to many previous
projects, Voith Paper not only has anenormous wealth of experience in India
but also the know-how to delivermachines for paper manufacturing
using bagasse. From stock preparation
to the winder, only proven components
were used for the PM 3. The machine
went into operation at the end of
December last year and began
producing copy paper for the growing
domestic market.

Fig. 1: Tamil Nadu PM 3 increases annual production capacity at TNPL to 400,000 tons.

18

32 I 2011 I Voith Paper I twogether

NEUANLAGENNEW PLANTS

Growth market India
Everyone who visits India for the

Why is TNPL interested in the export

first time is impressed by the size

business when there is an intensely

and the population density of thegrowing domestic market in its own

country: 1.2 billion people live there,

backyard? Paper manufacturing

and around 20 million are added toexperts on site assume growth rates

that each year. This remarkablein the range of 25% for some grades.

population growth is the same as thetotal number of Australia’s current

A. Velliangiri, Deputy Managing

residents added every year. The

Director at the TNPL paper mill,state of Tamil Nadu alone, whereexplains: “Just because we have a

TNPL is located, has over 65 million

rapidly growing home market doesn’t

residents. This one state thus hasmean there is a free-for-all to make amore residents than most European

profit. Far from it, India is a highly

countries. And where there arecompetitive market with just as toughpeople, paper is also needed.

price competition as anywhere else in
the free markets, so exports are

Tamil Nadu is in the south of India.

extremely important and an area we

The state is ideally suited as aare seeking to grow, particularly

location for a pulp and paper millin the high-quality paper segment.”

the size of TNPL. The reason is theample supply of pulp and easy
access to various markets, bothFig. 2

domestic as well as export markets.

400th NipcoFlex shoe press

component in the paper industry.

Other highlights of the PM 3

goes to TNPL

Especially when high dewatering

include:capacity is required during the papert High-turbulence headbox for

One of the special features the PM 3

manufacturing process, the advantages

has is the Tandem NipcoFlex shoeof this press concept are presented.

Fourdrinier and hybrid formers,

press. TNPL received the 400th press

Meanwhile, four NipcoFlex presses areequipped with a CD basis weightof this kind, which emphasizes the

now in use at the Indian company after

control, which ensures evensuccess and the popularity of thethe most recent delivery to TNPL.

formation.

t For additionally improved>>> Info: bagasse – sugar cane waste product
The term “bagasse” comes from the word “bagazo”, which means “waste” in Spanish. Bagasse is thepithy residue that remains after the sugar is removed from sugar cane. Paper manufacturing with a sugar
cane waste product once again demonstrates the considerable capabilities of the paper industry for
producing feasible quality products from residual materials.
Bagasse has a number of useful characteristics as far as the production of pulp is concerned: It is mucheasier to harvest than pulp wood and it requires significantly smaller amounts of bleaching chemicals inorder to get a clean white paper web. Nearly all grades can be produced from bagasse pulp, includingbank note paper and newsprint. However, producing high-volume paper with bagasse as the raw material
continues to be a challenge.

form stability and minimized
shrinkage, the first five dryer
groups are built in single-tierdesign and the last two groups
in two-tier design.

t Pre-dosed size press with on-line
size and pigment application,
to apply up to 1.5 g/m2 ofstarch or up to 5 g/m2 of color
pigmentation per side.

32 I 2011 I Voith Paper I twogether

19

NEW PLANTS

MasterJet F/B Fourdrinierwith ModuleJet with DuoFormer D Tandem NipcoFlex press

SpeedSizer

CombiDuoRun
after dryer section

EcoSoft
calenderTopDuoRun pre dryer section

MasterReel

VariFlexFig. 3: Machine concept
PM 3.

t EcoSoft calender with an elastic nipother products. For instance, thiswith a capacity of 300 tons/day forto ensure the required sheet

area of India is increasingly gaining

supplying its paper machines withsmoothness and gloss levels fora reputation as being a center forcolor-stripped pulp is the next project

uncoated and pigmented grades.

high-quality printing, and printerspending at TNPL.

t Fourdrinier former with TopFormer,

here are installing all the state-of-the-which was specifically developed

art printing presses from the likes offor counteracting two-sidedness

Heidelberger Druckmaschinen andwith good form stability.

manroland. These machines are
running very high-quality output atSince the startup of the PM 3 at thevery fast speeds and demand aend of December 2010, TNPL has

paper that not only allows ease of

Location

been producing copy paper for

putting ink on paper, but one thatIndia

the domestic Indian market. T. K.

has unquestionable runability

Ramachandran, Managing Director

qualities. That is what we can doat the TNPL paper mill, stresses

with our paper made from bagasse,that “without the active participation

particularly with the tandem shoeand involvement of Voith, the quickpress and EcoSoft calender features

startup of the new PM 3 would

on the PM 3.”

Kagithapuram
Tamil Nadu Newsprint
Papers Ltd.
The location for the new paper machine ishave been impossible.”20

New Delhi

The company is currently also

Kagithapuram in Tamil Nadu, the southern-

Quality requirements of printing

considering other countries as

most state of India. Covering an area ofplants met

possible export targets. A. Velliangiri

130,058 km², this state is almost as large

explains: “Last year we exported

as Greece.

Along with copy paper, other gradesaround 50,000 tons of various

are also planned that should provide

grades, and we expect this to

TNPL with a competitive advantage.

increase going forward. Although

A. Velliangiri, Deputy Managing

we have a growing market, exports

Director explains: “With PM 3 now,

are massively important particularly

we have all sorts of opportunities toin the quality areas.”

reach other markets and supply

Installation of a de-inking system

Contact
Carl-Heinz Becker
carl-heinz.becker@voith.com

32 I 2011 I Voith Paper I twogether

NEW PLANTS

Dandeli PM 6 successfully started up

A new age of paper production at the Kali RiverThe Dandeli PM 6 of >>> West Coast Paper Mills Ltd. (WCPM) successfully started up in May of 2010
in Dandeli, India, and already in December the Final Acceptance Certificate was signed. The PM 6
produces high-quality writing, printing and copy paper in the basis weight range of 45-90 g/m² at a wire
width of 5,850 mm and a design speed of 1,200 m/min. The investment of WCPM in a sixth machine at
the Dandeli location should almost double paper production and open up new levels of quality.

From the beginning, the paper quality

Bangur continues: “After some

new PM 6, Voith has truly acted asof the PM 6 was impressive and the

optimization and fine tuning work

our partner in this WCPM’s Megaplanned production quantity waswith this latest production line,

Expansion Project.”exceeded only a few months after

we have produced high quality

startup. Saurabh Bangur, Director of

copier grades efficiently and cost

Simultaneous completion of

WCPM, is very satisfied with theeffectively, which have been very

all systems

course of the project: “With Dandeli

well accepted in the market. All thePM 6, one of India’s most modern

quality expectations have been

One reason for WCPM’s investment

graphic paper machines was installed

achieved and very well established

was to increase the annual pro-in record time. This is the best start-

with very close teamwork between

duction capacity from 163,000 tons

up I have ever experienced or even

our team and Voith. With ato 320,000 tons. The higher needheard of, and we achieved its rated

combination of automation, plantfor pulp was covered by construction

operating speed of 980 m/min withinengineering and services along withof a new facility for production ofa very short span.”state-of-the art technologies in ourbleached pulp. Another component

Fig. 1: Dandeli PM 6 – convincing paper quality from the beginning.

>>> Info: West Coast Paper Mills
Commercial paper production at the current West Coast Paper Mills Ltd. in Dandeli,India, began in 1959. Today WCPM, which belongs to the S. K. Bangur Group, is oneof the largest paper manufacturers in India. At the Dandeli location, graphic paperand board are produced on several machines. Annual production, which in 1959
was still at 18,000 tons, was increased to 163,000 tons in 2003 and 2004 throughvarious expansion and modernization measures. Now annual production has nearly
doubled with the new PM 6.

32 I 2011 I Voith Paper I twogether

21

NEW PLANTS

Fig. 2: DuoFormer D and DuoShake ensure high paper quality in theforming section.

Fig. 3: Strong cooperation between Voith Paperand WCPM allows smooth startup.

of the project was modernization

Machine concept meets highSince long fiber pulp would have hadof the existing power plant.

requirements

to be additionally purchased, use of
100% short fiber pulp was required

The big challenge for everyone

Since premium writing, printing

for all grades and speeds, as wasinvolved was the nearly simultaneousand copy paper was going toabove-average efficiency andexecution of projects. Completion

be produced on the new paper

runability of the paper machine.

of the pulp facility thus overlappedmachine, the requirements wereA future increase of production

with construction of the paperhigh from the very beginning. Along

speed to 1,200 m/min was also tomachine and expansion of the powerwith very good profiles, excellent

be taken into account.

plant. Behind all the planning wasformation and a low MD/CD tensile

the goal of having sufficient pulp

ratio, a low level of roughness

The optimal machine concept wasand electrical power available forand high volume were especially

finally developed together with thethe startup of the Dandeli PM 6.

important.

customer and included tests at

Fig. 4: Dandeli PM 6 scope of supply
Along with the whole paper machine, including the stock preparation and the approach flow system, Voith Paper delivered an automation package that includes
the entire machine-oriented control, process control technology and a quality control system. By means of the roll covers, fabrics and doctor blades, high systemefficiency was ensured beginning with the startup of the PM 6. In addition, the accessories of the PM such as the hood, process air technology, plant air
technology, mechanical drives and the central lubrication system were also included in the delivery from Voith Paper.
MasterJet F/Bwith ModuleJet

22

Fourdrinierwith DuoFormer D

Tandem NipcoFlex press

TopDuoRun pre dryer section

32 I 2011 I Voith Paper I twogether

NEW PLANTS

Voith Paper’s Heidenheim Paper

But this was not the only challenge

Technology Center. In the area of

during the project. Due to thesheet formation, the provenmonsoon that started in June of 2008,

DuoFormer D and a DuoShakework on the building advanced only

provide for paper quality that evenslowly since the heavy rainfall

exceeds the high expectations of

put the site under water at times.

WCPM. The installed Tandem

Nonetheless, the first specialist from

NipcoFlex press has two advantages:

Voith Paper was already on site infirst of all, high dry content and thus

March of 2009. The specialist washigh production potential; andthere to ensure that no time was lost

secondly, it is attractive due to theand that as much work was done as

closed web run with the bestearly as possible. At the same time,

runability. The dryer section,

the specialist supported WCPM in the

SpeedFlow and soft nip calender

final preparation of the building andare state of the art for the paperwith logistics in the area of machinequalities produced.

assembly.

At the customer’s side fromOnly half a year after startup of thethe beginning

paper machine, WCPM had its first

Location
India
New Delhi

DandeliWest Coast Paper MillsThe Dandeli location is in the provinceof Karnataka, ca. 650 km southeast of
Mumbai. Surrounded by a dense forest,
the location on the banks of the Kali Riverwas selected due to its favorable situation.
The state of Maharashtra’s promise toprovide a continuous supply of wood as
the raw material, the availability of waterfrom the Kali River and power supply fromthe state network, among other things,
were reasons for the location decision.

discussions with Voith Paper about
The intensive collaboration between

an increase of production speed to

WCPM and Voith and competent

1,200 m/min. Due to the potential,

project management were critical toespecially in the press section, thatthe project’s success. The demanding

was possible without any additional

task of simultaneously working onlarge investment.

Contact
Carl-Heinz Becker
carl-heinz.becker@voith.com

several systems could thus be

SpeedFlow

accomplished. Together with the

For further support with optimizations

PM 6, the new pulp facility and theand with troubleshooting, a team ofmodernized power plant went into

automation and process engineersoperation on time. For WCPM thiswill be available to the customer on

was a clear economic advantage,site until the end of the firstsince there was no downtime.

production year.

CombiDuoRun
after dryer section

EcoSoft MasterReel
calender32 I 2011 I Voith Paper I twogether

VariFlex

23

REBUILDS

Fig. 1: A free benchmark test for an
initial energy efficiency evaluation of
screening systems is available online:
www.ScreenFitNavigator.com.

ScreenFit Compass 2011 analyzes screening systems

Study: 70% worldwide waste energy
In the benchmark ScreenFit Compass 2011 study, Voith Paper analyzed 80 fine-screening systems ofvarious generations, makes, models and sizes. The results were clear: 70% of screening processes
analyzed worldwide use energy inefficiently. That is an ailment Voith “ScreenFit Doctors” can help
cure. They offer expert advice and support to papermakers about rebuilding projects to avoid wasted
energy. Voith also offers, via the Internet, a quick analysis of how well or poorly a paper manufacturer’s
existing screening system performs with regard to energy efficiency.

24

The ScreenFit Compass process

have clear possibilities forcases, Voith Paper ScreenFit Doctors

identified only 24 of the 80 systems

improvement. The remaining 44

can provide sustainable solutions foras energy efficient. Twelve were in thesystems proved inefficient, with a very

an energy efficient screening process

mid range for energy efficiency andhigh optimization potential. For suchin stock preparation.

32 I 2011 I Voith Paper I twogether

REBUILDS

The findings rated the energy

ongoing innovations. Over the past

consumption of various manufacturers

few years, the relationship between

based on stock consistency,

screen basket size and screen

screening efficiency, operating modesurface has constantly increased withand paper grade. A full cascade

C-bar family baskets while slot widths

system consumes more specifichave stayed constant. As the latest

energy than a partial cascade system

screen baskets get smaller in size,

because the full cascade returns

production capacity increases, andstock to the upstream stage.

screens once operated in parallel can

Operating in full or partial cascade,be switched off. Investment andhowever, depends upon technicaloperating costs can thus befactors such as screening efficiency

substantially reduced.

and cannot be made dependent on
the specific energy requirement. The

Along with the right choice of screen

specific power input refers only to thebaskets and rotors that match themscreening machines in the study.

(e.g., the MultiFoil rotor), stock

Pumping energies were not taken into

consistency and the interconnection

account in the calculation.

of the individual screening stages
contribute considerably to specific

The trend is toward innovative

energy consumption. For this reason,bar profiles

modern Voith stock preparation
concepts aim at increasing stock

The wrong choice of screening
concept or operation of obsolete
systems appear to be the maincauses of the poor results in the
In the study, the designs of 80 stock

ScreenFit Compass 2011. To counter

preparation systems worldwide were

those poor results, Voith Paper offers

compared to the current state-of-the-its C-bar screen basket line, which

art technology.

continues to be enhanced with

Fig. 2: Significant examples from the
ScreenFit Compass 2011 benchmark
study of screening systems for board
and packaging paper. The study clearlyshows how often specific power input
is well exceeded. Systems in the grayfields correspond to the current state oftechnology.

Screening of board and packaging paper in low consistency (LC) application
Partial cascade15

10

Low stock consist

encyHigh stock consistency

5
300

500

900
700
Mass ﬂow [t/24 h]

32 I 2011 I Voith Paper I twogether

Full cascade

20

Speciﬁc power input [kWh/t]Speciﬁc power input [kWh/t]

20

1,100

1,300

15

Key
Energy inefﬁcientreference systems

Low stoReference systems
in the energy efﬁciency
mid range

ck con105300

sistencyHigh stock

500

Energy efﬁcientreference systems

consistency

900
700
Mass ﬂow [t/24 h]

1,100

1,300

25

REBUILDS

Before rebuild
500

449

400

500
410

400
300

300
200

200

-9%

147

112

Sticky concentrationin accept* [mm2/kg]

Energy consumption [kWh]

Maxau

600

600

After rebuild

100

100
-24%
0

Reduction ofenergy consumption

Reduction of
sticky concentrationin accept

0*Method: Ingede

Fig. 3: Reduction of sticky
concentration and energy
consumption after conversion to
C-bar R in the first stage and to
C-bar Q in the final stage of thescreening system in Maxau. Oneof the three first-stage screens
could thus be shut down.

consistency and improving thescreening, with three Voith vertical

Free benchmark test on therelation between energy input andscreens working in parallel in the first

Internetscreening efficiency.

stage and one screen each in the

The compact design of the new

second and third stage were all

Voith Paper has now created a way toequipped with Voith C-bar S baskets.

subject the fine screening for brownand graphic paper to a quick, non-screening systems reduces the sizeof the stock preparation, which in

The intake stock consistency in thebinding self test via the Internet

turn leads to lower investment costs.

fine screening can be classified as(www.ScreenFitNavigator.com). The

However, choosing the right screen

low. The conversion to C-bar R for the

calculation for this initial check isbasket depends not only on open

first two stages and C-bar Q screen

based on the results of the screening

screen surface but also on stockbaskets for the final stage meant thesystem study. System operators needparameters, such as fiber length.

entire open screen surface of all

only name the system type, identify ascreens increased nearly 50% – withfew parameters, and give information

ScreenFit Doctors alreadythe same slot width. After shutting

on the main quality focus for the

successful in practicedown a vertical screen in the firstscreening. The program then draws

stage, sufficient screen surface stillup an initial energy evaluation of the

The ScreenFit Doctors have provenremains. With improved stickies

screening system. The energy

successful several times, such as inremoval, the annual energy saving isefficiency of the system becomes

the southern German StoraEnso

about 300,000 kWh. A future

visible on a color bar from green to

Maxau paper mill, where graphic

throughput increase remains anred.

paper is produced. The full cascade

option for the operating company.

Screening after the rebuild
6.3 kWh/t

5.0

5.5

6.0

6.5

Fig. 4: As a result of the self test with the
ScreenFit Navigator, every user gets a firstestimation of the energy classification forthe system.

Screening before the rebuild
8.2 kWh/t

7.0

7.5

8.0

8.5

9.0 kWh/tContact
Tobias Kolhagen
tobias.kolhagen@voith.com

New Voith system

26

Mid range with clear
optimization potential

System with highoptimization potential

32 I 2011 I Voith Paper I twogether

REBUILDS

C-bar M screen basket completes screening portfolio

Stability is key
Maximum screening quality and minimum energy use are the hallmarks of a screening system thatworks well. Screen baskets provide the key to unlock such effectiveness. With the C-bar M, Voith Paper
expands a proven series that already includes five high-capacity models. Exceptional stability
distinguishes the new screen basket – stability achieved from cambered profile bars and reinforced
trussing rings.
The C-bar M is suitable for all

More throughput and 15% lessAlong with an increase in efficiency,

centrifugal pressure screens inenergy required

Weig Karton also noticed improved
final quality. Further, the paper

graphic or brown-screening systems,
and it can be used not only for stock

The success achievable by converting

manufacturer achieved these results

preparation but also in broke andto a C-bar M screen basket isby purchasing the C-bar M baskets forpulp screening. Its strength is its

illustrated by Weig Karton, a leading

30% less than a milled screen basket

maximized open screening area,

producer of recycled board in Mayen,would have cost – a convincing fact.

yielding above-average screening

Germany. Before the rebuild, two

results. C-bar M complements

conventionally milled slotted screen

The positive results persuaded Weig

aggressive rotors and can replacebaskets were installed in the

Karton to also replace the basket inconventionally milled slotted screencompany’s two-stage screening

the first-stage screen with a C-bar M

baskets.

system. By replacing a basket inin order to take advantage of thethe second screening stage with aremaining potential for the entire

While the profile bars are clamped in

C-bar M screen basket, the open

screening line.

the case of C-bar S, Q and R, thescreening area was doubled.

bars of C-bar M are cambered asConsequently, daily throughput

well. The design is more stable andincreased from 35 to 41metric tons.

thus suitable for applications where

At the same time, rotor speed wasclamped designs cannot be used,

reduced by 2 m/s to 22 m/s. As asuch as high stock consistencies

result, energy consumption fell by

and high rotor peripheral speeds.

15%.

Contact
Christian Steinmassl
christian.steinmassl@voith.com

Fig. 1 and 2: More stable than the others: With its cambered profile bars and reinforced trussing rings, the new C-bar M is especiallysuitable for challenging screening applications.

27

REBUILDS

Fig. 1: The VariTop winder, a milestone inwinding technology.

Complex rebuilding projects in three to seven days

Getting winders moving again
If the large reels pile up at the end of the paper machine, it’s often due to obsolete, slow winders. Herea rebuild brings the technology up to state-of-the-art in just a few days. In the last three years, Voith
Paper has done about 40 such rebuilds. New controls are particularly successful in leading to noticeable increases in production.
Since paper machines are being builtwith replacement parts often being

be perfectly coordinated with one

with more and more capacity, theunavailable and expensive. A rebuild

another.

winder – often an older one – cannot

can rectify these disadvantages withkeep up with the pace. The higher

minimal production stoppage and low

Voith Paper offers customized rebuild

volume of paper produced is notcosts, because usually a time frame

solutions for the various single-drumwound quickly enough ontoof three days or at most a week isand two-drum winders and supplies

transportable rolls. In addition, theinvolved when a stoppage is required.

all related products and processes

old winders may cause significant

For an optimal result, automation,from one source. In the process, thedowntime and are difficult to repair

mechanics and technology have totechnological know-how from the new28

32 I 2011 I Voith Paper I twogether

REBUILDS

Fig. 2: The individual roll structure of the VariTop.

Fig. 3: The commissioning engineer takes a scrutinizing look at the pressure rolls.

machine business is incorporated inreplacement parts for S5 components,

In the case of a rebuild, modern

the planning and execution of rebuilds.

specific electronic assemblies andcontrols and drives are used withThus new technical developments alsofrequency converters is no longer

which the customer is familiar based

come to fruition. At the same time,assured.

on existing systems in the paper mill.

further developments for new
machines arise through the work on
rebuild projects. In the last three years

Fig. 4: The slitter section, one of the core components of the winder.

alone, Voith Paper has carried out
about 40 small and large rebuilds ofwinders.
Controls like with new machines
Winders that are now having to berebuilt or replaced were generally built
sometime between the early 1980s
and mid 1990s. Since then, controls
and computer technology havebecome highly developed. In the areaof controls, the availability of

32 I 2011 I Voith Paper I twogether

29

REBUILDS

Always under time pressure:

Success depends on thecommissioning engineers
Along with sophisticated technology,“In order to make such comprehen-

the competence of the commissioning

sive changes in such a short time,engineers is essential in thedetailed planning, reliable technology

successful rebuild of a winder. This isand good coordination and commu-

evident in the rebuild of VariTops that

nication onsite are needed,”

Voith Paper undertook in Japan. At

says Sven Franke, Project Manager

issue were single-drum winders built

for winder rebuilds at Voith Paper

in 1989 onto which each roll is

Automation.

individually wound. Before therebuild, positioning of the knives

In a first step, many customers will

and winding stations and line loadrequire only a comparatively small

control of the machine was done

rebuild such as a computer upgrade,with a separate electronic unit. The

he explains. But Franke has also

electronic unit was connected todone a complete replacement of thethe machine control via a hardware

control or system. According to him,interface.

the biggest challenge is doing therebuild in the specified short time.

In only five days, Voith Paper

Experience is therefore critical.

Automation replaced the machine“In each case, it is important to know

control, performed a hardware up-

the old system and to have an exact

grade from S5 to S7, and integrated

idea of how the new one should

the functionality of the old electronic

work,” says Franke. Then, time isunit in the machine control.

also on his side.

Fig. 5: Commissioning engineer, Sven Franke,
checks the winding quality of the roll.

winder drums are necessary, this canbe tested in advance by Voith Paper.
Drives are likewise calculated andreplaced by motors with more capacity,
if necessary.
Rebuild or a new machine?
For paper manufacturers withbottlenecks at the winder, there is ofcourse also the option of investingin a new winder. Deciding in favor ofa new machine often means higher
productivity. But production undergoes
a longer downtime due to dismantling,foundation work and subsequentThis guarantees trouble-freewhich allows a smaller hardware

new construction and startup. In

maintenance of the machine in theoutlay and better, easier service.

many cases, the downtime andfuture.

higher investment costs are points
There are numerous possibilities, notthat make a rebuild a more attractive

The solutions delivered by Voith Paper

only for ensuring availability, but also

option.

are certainly not just replicas of old

for further developing the components

systems. Rather, the technology

both technically and technologically.

used is based on that of new

Therefore, by increasing the degree ofmachines. The current standard isautomation, productivity and machine

open control systems, i.e., integration

safety can be increased. Automaticof black boxes and digital controls insequences at unwinding and/or wind-the machine control. The safety

up, end sheet gluing or automatic

technology is integrated in a safety

knife adjustments can serve as

PLC (programmable logic control),examples of this. If coatings for the30

Contact
Egon Bildegon.bild@voith.com

32 I 2011 I Voith Paper I twogether

PRODUCTS ON SITE

IntensaMaXX reliably removes contaminants

Trouble-free pulper detrashing operation
A kidney has the task of removing foreign material and purifying the body. Working in much the sameway, the new patented IntensaMaXX is the kidney of the TwinPulp pulping system. As a component ofstock preparation, it separates up to 80% of contaminants out and thus prevents the much-feared“pulper infarction.”

Like a kidney, the stock preparation
can also suffer from colic – namely,when unpleasant contaminants
obstruct the detrashing system.
Especially pernicious are spinnings

Fig. 1: The analogy
to anatomy: The
IntensaMaXX as
the kidney of the
TwinPulp pulping
system.

that can arise in a matter of seconds
due to wires, strings, nets or large
films. For the paper manufacturer,that usually means expensive andnerve-wracking maintenance work,
since the spinnings have to becarefully removed from the pulper
detrashing machine.
The IntensaMaXX offers a promisingsolution to this problem. As thenewest product in the proven
Intensa line, it guarantees
outstanding pulper detrashing andnearly total malfunction elimination.

Concentration of contaminants [%]
50
40
30
20
10
0
Recoveredpaper

PulperIntensaMaXX

Fig. 2: Typical portion of contaminants in
preparation of recovered paper.

32 I 2011 I Voith Paper I twogether

31

PRODUCTS ON SITE

The eccentricity already seen in the
IntensaPulpers IP-R and IP-V iseven more strongly pronouncedwith the IntensaMaXX. The
particular orientation of the rotorscreen unit in the asymmetricallyshaped tank ensures that novortices form in the IntensaMaXX.
Development of spinnings is thus
successfully counteracted.
Contaminants do not impair
operational reliability
The IntensaMaXX is a componentof the TwinPulp system that removes
contaminants from the paper. While
recovered paper fibers are dissolvedin the pulper, indissoluble
contaminants accumulate in it
until they reach a concentrationof ca. 15%. For comparison: At
about 5%, the raw material fed inat the start of stock preparation
has a noticeably lower impurity
content.

Fig. 3: Three-dimensional model of the IntensaMaXX.

The accumulation of contaminants3

in the pulper can substantially4

impair its capacity. As the TwinPulp

5

diagram shows, a portion of theDrum screen

accumulated contaminants is for

IntensaMaXX

this reason continuously pumped

6

out of the pulper (1) into the
H 2O

4

2

IntensaMaXX (2). Here they further
accumulate while the purified partial

IntensaPulper IP-R

1

stream (3) flows back to the
IntensaPulper. Starting at acontaminant concentration of ca.
50%, the washing water washes
the fibers out of the IntensaMaXX

2

and back into the pulper; afterward,
the contaminants are routed tothe drum screen (5). From there,

Fig. 4: IntensaMaXX in the TwinPulp system, the continuous LC pulping system forrecovered paper grades containing contaminants.

32

excess water goes back into thepulper while the largely fiber-free,

32 I 2011 I Voith Paper I twogether

PRODUCTS ON SITE

pre-dewatered contaminants (6)TwinPulp pulping system. A

are further dewatered in the rejectretrofit is also possible in existingpress.

systems.

The asymmetrical tank form of theIntensaMaXX ensures smooth

On Focus: IntensaMaXX
ProRunability
Section: stock preparation
Paper grade: all recovered paper grades

operation during the entire pulper
detrashing process. Stoppages

Contact
Wolfgang Müller
wolfgang.mueller@voith.com

due to spinnings are a thing of
the past, even at the highest
concentrations of contaminants.
Through the downward dischargeof contaminants, heavy parts
are particularly well managed:
They are reliably discharged atintervals without endangering
operational reliability.
Clean pulpers and fiber-free
rejects at Varel
At Varel, the German paper andboard mill, an IntensaMaXX has
been reliably detrashing therecovered paper pulp for twoboard machines since December
2010. There, two pulpers of the
AP type pulp mixed recovered
paper and supermarket OCC
with a total capacity of 600 metrictons/day. The IntensaMaXX is
responsible for the detrashing ofFig. 5: IntensaMaXX successfully used in practice for stock preparation at the
Varel GmbH & Co. KG paper and board mill, Germany.

the two pulpers simultaneously“through process sequencing.”
The result has convinced thecustomer: The pulpers are cleaner
than ever and the rejects fiber-free.
Thanks to its impressive
performance in contaminantremoval and operational reliability,
in the future the IntensaMaXX will
be preferably used by Voith Paper
in all new systems. Together with
the IntensaPulper IP-R, it forms ahigh-performance unit in the

32 I 2011 I Voith Paper I twogether

Fig. 6: Normal contaminants, which the IntensaMaXX
separates and which are removed from thedownstream drum screen.

Fig. 7: Strange contaminants
often have to be removed from
pulping systems.

33

PRODUCTS ON SITE

DuoShake and CarboForm – an unbeatable combination

High-frequency shaking preserves resources
The interaction between the light CarboForm roll and the DuoShake shaking unit has already provenitself more than 30 times worldwide. And with noticeable success: The combination lowers resource
consumption and saves operating materials. In addition, paper quality is even further improved.

The DuoShake shaking unit has

processing, coating, impregnating

Higher shaking frequency andbeen demonstrating its advantages

and printing of the paper.

better paper formation

functional principle allows shaking

With the three different DuoShakeThe fiber composite design of thefrequencies that cannot be achieved

sizes, Voith Paper has the ideal

CarboForm was specifically developedwith conventional shaking units. A

component for every application –for the requirements of high-frequency

more homogeneous fiber distribution

from smaller, slower machines all the

shaking with the DuoShake. The highis thus achieved, even with fast-

way up to machines over 9 m wide

form tolerance of the roll, for example,

running machines. In addition, thewith speeds as high as 1,200 m/min.

makes a decisive contribution to its

formation is improved, and the

The potential of the DuoShake cansuccess. The CarboForm is

tensile strength ratio is reduced,

be fully utilized in combination withlightweight: With only about 40% of

which is indispensable for gooda CarboForm roll. Many advantages

what a comparable steel roll weighs, it

dimensional stability. Other

result from this, such as theallows higher shaking numbers andadvantages result with further

improvement of paper quality.

leads to better formation of the paper.

in 170 systems worldwide. Its

In addition, lower shaking forces areneeded with identical shaking
Fig. 1: DuoShake unit allows the highest shaking frequencies for the breast roll.

parameters.
The CarboForm and DuoShakecombination is already used in over
30 installations worldwide and isvery successful in each one of them.
A paper manufacturer in North
America that produces testliner on
a 4.7-meter-wide, two-layer Fourdriniermachine installed two DuoShakes
together with CarboForm breast rollsin 2008 and 2009. The result was aclear reduction of the basis weightwith identical strength values andincreased machine speed.
Lower consumption of resources
pays off
Along with an improvement in quality
parameters such as formation,

34

32 I 2011 I Voith Paper I twogether

PRODUCTS ON SITE

Fig. 2: CarboForm carbon fiber reinforced plastic roll is lightweight.

MD/CD tensile ratio, tensile strength,

80%

energy absorption and transverse

60%

strain, fibers and operating materials
can be saved. The DuoShake and40%

CarboForm roll combination reduces

20%

fiber use, refining and use of starch,0%for example, while maintaining-20%

quality parameters. In addition, themachine speed can be increased.

-40%

Especially good results are obtained-60%with brown papers such as-80%

corrugated cardboard base paper,

On Focus: DuoShake and CarboForm
ProEnvironment

Shaking
numberhigherby 57%

ProRunability
ProQuality
ProSpeed

Carbon ﬁber
reinforced plasticroll is60% lighter

Section: former
Paper grade: all
Contact

Shaking number

Mass

Walter Blum
walter.blum@voith.com

board or sack paper.
All in all, this leads to lower
consumption of fibers and operating
materials, so that such an

Fig. 3: Advantages of a carbon fiber
reinforced plastic roll as compared toa steel roll.

Sebastian Dienst
sebastian.dienst@voith.com

investment pays for itself very
quickly and at the same timepreserves resources.

32 I 2011 I Voith Paper I twogether

35

PRODUCTS ON SITE

Tailored automation package enhances process stability

Rondo Ganahl saves costs with new quality control system
As a premium manufacturer of testliner and white top linerboard >>> Rondo Ganahl invested in a new
quality control system for its PM 2 in Frastanz, Austria, in order to increase paper machine efficiency
and consistently meet its customers’ quality demands. The previous model needed extensive repairs
and only limited upgrades were possible due to the age of the system. With a view to leveling theinterfaces of the diverse automation environment and making the system easier to service, Rondo
Ganahl opted for a rebuild in collaboration with Voith Paper.

The rebuild allowed Rondo Ganahl toalso allowed for a faster response

achieve considerable improvements

time. In addition, the measurement

in its efficiency. Before the rebuild,system reduces the response time in

the measured moisture content was

the event of process fluctuations,

too low because there was no ash

ensuring consistent quality. The

measurement, and this consumed

system has been running smoothly

unnecessary drying energy. Using

since it went on stream.

the ash sensor, combined with thebasis weight sensor it is now possible

Lower maintenance, servicing

to accurately determine the final

and training costs

moisture content. This reduces fiber
consumption by about 1%, while

The existing measuring system wasdrying energy is reduced by about

replaced by a new Voith LSC scanner

2.5%.

with moisture, ash and basis weight>>> Info: Rondo Ganahl AG
The headquarters of Rondo Ganahl AG, a
company steeped in tradition, are located in
Frastanz, Austria. They have been making
paper here since 1911, and the company
will celebrate its centenary this year. Today,
Rondo Ganahl AG produces corrugatedboard in the basis weight range of120-200 g/m2 on its modern PM 2 paper
machine. At a machine speed of up to
900 m/min and a web width of 2,500 mm,
it produces an average of 100,000 t/year
high-quality white and brown testliner
grades from 100% recovered paper. With
its white testliners, the company occupies
a leading role in the key markets of Germany
and Austria.

measurement and a color sensor.
Installing a color sensor allowed the

The very limited space available

Voith LSC measurement system willamount of broke to be reduced when

upstream of the winder necessitated

reduce maintenance and servicing

switching paper grades from brownhigh-precision workmanship whencosts for the PM 2 in the future andto white testliners. The display of theinstalling the scanner. The rugged,

will pay dividends in the long term.

chromaticity coordinate on the monitor

easy-to-maintain features of the

The complete integration of theFig. 1: Using the Voith LSC scanner allows maintenance and servicing
costs to be reduced.

36

Fig. 2: OnQ ModuleTap actuators control the existing dilution
water headbox.

PRODUCTS ON SITE

Voith Paper automation package into
the existing PCS 7 environment makes
the system easy to maintain.
Thanks to the standardized platform,
the delivery of training andconsolidation of know-how among
operating and service personnel havebeen greatly simplified.
To allow optimum basis weight CD
profiles to be achieved, the automation
package also included OnQ ModuleTap
actuators that control the existingFig. 3: View of PM 2 in Frastanz, Austria.

dilution water headbox. Theseactuators are known for their reliability

speed of the control function isgrammage change is achieved by theand ease of use. Whereas previously

enhanced by the fast traversing speed

map-based, feed-forward control ofthe process control system did notof the basis weight sensor.

the relevant process variables. In theprovide error messages, Rondo

process, moisture is kept constantGanahl’s papermakers now get a

5.6 metric tons more per grade

and no longer has to be ramped

status message if there are anychangedown. A grade change involving a

failures. This forms the basis for adifference of 5 grams can be carried

diagnosis of the problem in order to

Also included in the automationout without producing any broke

improve process stability. Optimization

solution were various OnQ

whatsoever. Where the difference isis done automatically via the adaptive

GradeControl MD controls, such as

10 g, the optimum quality is achieved

control of the OnQ Profilmatic control

a multi-ply controller and jet-to-wire-

after just 3 minutes. Even a grade

software, ensuring a consistently highspeed ratio controller. The highlightchange involving a difference of 30 g

paper quality. It is perfectly tailored tois the OnQ GradeManager; thiscan be carried out in a very short time,

the OnQ ModuleTap actuators and theautomatic grade changer substantiallyin as little as 6.5 minutes. In total thisquality control system and thus

reduces grade change time and theamounts to an additional production

achieves optimum measuring andbroke resulting from start-up waste.

volume in A-grade quality of 5.6 t percontrol performance. In addition, theThe optimum transition during a

grade change.

“We would choose to partner with Voith again any time.”
Maik Willig, Plant Manager, Rondo Ganahl Frastanz, Austria“The commissioning phase was incredibly fast. Right after startup the measuring systems were functioning and themachine produced paper in saleable quality. I have seldom experienced such a smooth startup. The cooperation
between Rondo Ganahl and the Voith team was excellent and very congenial – in my view this is why the launch
was so successful. We would choose to partner with Voith again any time.”

32 I 2011 I Voith Paper I twogether

37

PRODUCTS ON SITE

“I would not have thought the whole process would go so smoothly.
Well I was wrong: Startup – widen – run! Voith Paper demonstrated extensive
expertise and delivered high quality.”

Maik Willig, Plant Manager, Rondo Ganahl FrastanzThis allows Rondo Ganahl paper-of servicing operations. In addition,

focused cooperation between the

makers to respond flexibly to

Rondo Ganahl was striving torelevant parties at Voith Paper andcustomer requirements and at thecontinually improve its paper grades

Rondo Ganahl meant the rebuild could

same time produce efficiently. In

and also minimize broke during grade

be carried out successfully within

addition, the automation haschanges.

three days of downtime. Both sides

considerably improved handling forwere very happy with the results.

the paper machine operators and

The company therefore opted for aleaves time for changing the headbox

new quality control system

aperture manually during a grammage

guaranteeing a standardized,

On Focus: Quality Control Systemchange.

integrated operating and engineering

ProSafety

interface. The contract award process

ProEnvironment

focused on a solution offering

ProRunability

complete integration into the existing

ProQuality

The initial quality control system was

PCS 7 control system. In addition, theProSpeedoriginally installed on the PM 2 inentire project was designed to use

1998. In 2003, as part of a retrofit, thefamiliar programs running in German.

Section: entire paper machine

dilution water controller was adapted

Even in the preliminary phase, Rondo

Paper grade: allto the new machine concept. The

Ganahl was very mindful of theexisting measuring system required

potential risks such as quality issues

extensive repairs that left little scopeor customer complaints whenfor improvements. The high level ofresuming production after the rebuild,

servicing and maintenance required

Voith Paper still stood out as theincreased costs for spare parts andpartner that could best meet all oftraining, as well as a greater number

Rondo’s requirements. The intensive,

Challenges mastered together

Contact

Fig. 4: With the new quality control system, the PM can be controlled entirely from the control room.

38

Klaus Steinhart
klaus.steinhart@voith.com

PRODUCTS ON SITE

Fig.1: Integrated drive solutions ensure easeof operation, fewer web breaks and improved
machine safety.

Synergy between mechanical engineering and automation

Fewer web breaks thanks to integrated drive solutions
Much can be achieved by a drive concept perfectly tailored to the paper machine: It enables simple
operation and ensures fewer breaks and a greater degree of machine safety. Furthermore,as all components are supplied from a single source, the paper producer has only one point of contact,paving the way for on-schedule, problem-free commissioning.
Integrating the drives into the machine

many benefits, for example, is a well-

Process technology know-how is crucial

design is very important for modern,coordinated drive control system thatin order to specify the interaction of theefficient paper production. One of the

reduces the number of web breaks.

various drives in combination.

32 I 2011 I Voith Paper I twogether

39

PRODUCTS ON SITE

In its capacity as a paper machineThis guarantees faster commissioning

and troubleshooting are faster andmanufacturer, Voith Paper has always

as well as quicker optimization of themore reliable. The software libraryspecified the mode of operation ofdrives and the machine itself.

developed by Voith Paper is usedthe drive systems for paper machines

for both the machine control andand winder systems. A large number

Drive control integrated into

for OnC DriveCommand, meaningof projects have provided Voith withmachine control systemthat there is no need to maintainextensive expertise in electricaldifferent controls and software

drive technology. This know-how is

In the past, the machine move-libraries and the programming

necessary to optimally design thements and drive functions were

philosophy is identical.

switchgear and to program anddesigned separately, although they

define the parameters of thehave an impact on one another.

As a result of the close cooperation

inverters.

OnC DriveCommand now

between experts from the drive

incorporates the drive control into

technology, mechanical engineering

In Voith, papermakers have athe machine control system.

and process technology sectors,

partner capable of supplying a

Handling is simplified due to thenew drive modules are also being

paper machine with a complete

uniform operating interface andconceived and implemented. They are

drive system comprising drivemachine operation, as all controls

immediately put to the test worldwide

controller, converters with associatedare located on one and the sameon the pilot facilities at Voith’s paper

switchgear and electrical motors.

system. This means that optimization

technology centers, ensuring fastdevelopment processes. The focus of
all these innovations is on machine

OnC DriveCommand
PCS 7 Platform

availability, paper quality and thesafety of machine operators.
OnC DC ES

OnC DC OS

OnV PDAOnC DC Panel

For example, a newly developed load
distribution algorithm reduces thesusceptibility to vibration of criticalIndustrial Ethernet Ring
Proﬁbus DP

drive positions, while controlling
CPU / AS 400

OnC DriveSystem (PM)OnC DC Server

OnC ConDrivemodeled paper web tension in criticalmachine sections improves runability.
This results in fewer web breaks andtherefore greater machine availability.
Highly dynamic converters are used
for particularly challenging control
tasks.
New emergency stop concept

OnC MoDrive

enhances machine safety
However, drive technology is not justabout modern control concepts;
machine safety is also playing an
increasingly important role. The

Fig. 2: The OnC DriveSystem comprises OnC DriveCommand, OnC ConDrive and
OnC MoDrive. OnC DriveCommand integrates the drive control into the machine control
system, allowing faster and more reliable optimization and troubleshooting.

40

switchgear supplied by Voith
Paper includes tried and tested
components.

32 I 2011 I Voith Paper I twogether

PRODUCTS ON SITE

Integrated system

papermaker to avoid budget
overruns. As everything is supplied
from one source there is no need forseparate tender and award processes
for the drives or for coordinatinginterfaces with other suppliers. Voith
Paper takes charge of coordinating

10

20

30

Voith

40

50

60

70

Drive Supplier

80

90

100

110

120

130 140
Workload [%]Customerthe personnel for commissioning
and ensures that the various project
sub-phases are completed on

Fig. 3: The lower bar in the chart shows the increased workload for the paper mill whereseparate systems are installed. Using Voith’s integrated solution entails much less work,as the upper bar shows.

schedule. Even during the
optimization phase there is only
one point of contact, thus avoiding
communication issues between

Enhanced safety is provided by thewith motors. This allows savings

suppliers. This allows production

emergency stop feature that Voithamounting to 2% of the entire energy

increases and quality enhancements

Paper has been using in turn-key

consumption of the drive system.

to be achieved sooner.

systems for some time now, where

Various drive concepts with different

the emergency stop system has been

configurations were compared andisolated from the drive technology.

investigated back in 2009, and thisThis now means that the operator canstudy is now the basis for selecting

identify, just from the display on the

motors. One improvement in this areamachine control monitor, where thehas been the VoithDrive, which ismachine came to an emergency stop

designed as a torque motor andand why. A false alarm is often thedoes not require a reduction gear,

reason for an emergency stop. For

so that there are no gear friction

the papermaker, this innovation also

losses. In addition, the permanent

represents improved operator andmagnet synchronous motor ismachine safety.

highly efficient. VoithDrive takes

Section: entire paper machineup very little space, making it ideal

Paper grade: all

Motors for lower total cost of

On Focus: OnC DriveSystem
ProSafety
ProEnvironment
ProRunability
ProQuality
ProSpeed

for retrofits too.

ownership

Contact
Total cost fixed from the very

The drive solutions also score highly

start

in terms of economy, as particularemphasis is placed on the energy

A fixed price for the entire systemefficiency of the entire drive train

including drive concept allows theWolfgang Klotzbücher
wolfgang.klotzbuecher@voith.com“Voith Paper supplied a complete electrical and mechanical drive system including a
ˇ PM 6. The drive system is working very reliably
complete automation package for the Šteti
and fully meets our expectations. We would opt for this solution again.”Lars-Erik Mellgren, Technical Director, Mondi Štětí a.s., Czech Republic

32 I 2011 I Voith Paper I twogether

41

PRODUCTS ON SITE

Breakthrough with tissue fabrics

Evolution improves dewatering in the press
In the fall of 2010, Voith launched a high-performing press felt for tissue machines.
Through the use of polymers, this press felt provides for optimal nip dewatering over its
entire life cycle.

In order to keep up with thepress felts, which play an importantvarious physical conditions within thecompetition, tissue manufacturers

role in the production of tissuepress section.

depend upon continuous

paper.

improvements in performance ofAn investigation of the performance

consumables for their machines –Therefore, as the first step incurve for conventional felts comparedsuch as fabrics and rolls. Energy

developing a new press felt, Voith

to the ideal capability of tissue felts

consumption, machine efficiency

analyzed all the possibilities for therevealed important behavioral

and stable operation are just a few

performance and structure of felts.

characteristics with regard to energyof the major concerns. All this is

Thanks to a new software program,consumption and life. The positive

substantially influenced by theit was possible to simulate thechange in felt porosity due to thecompression forces and the flow ofwater through the felt can also be
observed here.
Polymers keep felt density at
an ideal value
Building on these new findings
and insights, Voith Paper developed
the Evolution press felt. It combines
existing technologies with a complex
new process that adds special
polymer particles to certain zonesof the felt (Fig. 1). The polymers
are able to adjust the felt density
to an ideal value and keep it there.
Outstanding dewatering characteristics are thus achieved in the nip.
Consequently, starting up with new
Evolution press felts requires almost
no break-in time.
In order to be able to determine
the most efficient use of the newmaterial, Evolution was extensively
tested in the Voith pilot tissue

Fig. 1: Three-dimensional felt structure.

42

machine in São Paulo, Brazil.

32 I 2011 I Voith Paper I twogether

PRODUCTS ON SITE

Total energy savings

Various felts with different polymers

On Focus: Evolution press felt

were operated under identicalstartup behavior could be observed.
After several customer tests all over
Europe, Evolution had undergone

ProEnvironment

Energy consumption

conditions, so that differences in

ProRunability
Standard felt

ProQuality

Energy savings

ProSpeed

extensive testing under genuine
Section: press

production conditions. The feedback
from tissue manufacturers was

Running time
Short start-up
phase

extremely positive.

Maximum
dewatering performanceover the entire running timeLess drying energy and fewer
chemicals

Paper grade: tissue
Contact
Lippi Fernandes
lippi.fernandes@voith.com

Fig. 2: Energy consumption.

Along with the advantages ofimproved dewatering in the nip andquicker startup times, Evolution

The successes with Evolution

can reduce the thermal drying

so far are springboards for further

energy required for the tissue web.

developments. Voith Paper is

It is kept at a low level over thecurrently working on expanding

entire life time of the felt (Fig. 2).

the test runs to other tissue

Running stability and performancemachines. In addition, tests

are impressive. In addition, it was

showed that Evolution indemonstrated in several tests under

combination with the newreal production conditions that fewer

SolarSoft polyurethane rollchemical cleaning cycles werecovers, which have a special

required – in some cases they were

surface texture, can achieveeven completely unnecessary.

even better results.

Klaus Grusemannklaus.grusemann@voith.com“For us, Evolution is clearly thebest felt that we have ever run.”
Jordi Goma Camps, Mill Manager at Goma Camps, Spain“We first tried Evolution felt in our PM5. The performance was very good interms of startup, energy savings, speed increase, flat profiles, stablerunability and less chemical wash. Then we tried it in PM6, where we
manufacture our DIP paper, and the performance was very similar, with
better performance compared to the rest of the felts.
Furthermore, usage of Evolution felts, have helped us to work towards the
reduction of the paper carbon footprint, which is one of our main targets.”

32 I 2011 I Voith Paper I twogether

43

NEW TECHNOLOGIESA new class of polyester monofilaments

More effective dryer fabrics thanks to SynStron
Heat and moisture – both are a challenge for polyester yarns of fabrics used in the dryer section.
Thus Voith Paper developed the SynStron yarn, a polyester monofilament (PET) that ensures alonger service life of the dryer fabrics. This is achieved through higher strength and hydrolysis
resistance.

The SynStron yarn was developed byfabric life of 446 days (15 months).

performance of the sheet control

Voith Paper at its R&D center that

This is equivalent to an increased life

system and optimal run of theworks exclusively on materials forof 30%.

paper web.

expertise brings successful products

Tests on fabrics that have alreadyHigher resistanceto customers. For example, a paper

run on paper machines include theproducer set a record life by using themeasurement of remaining seamDryer fabrics made from standard PET

new SynStron monofilament in astrength and air permeability. In themonofilaments are normally removed

PrintTech-S Q2 dryer fabric from Voith

case of the fabric mentioned above,from the machine due to damage,Paper. The fabric ran in the third

the seam strength remained high at

abrasion or degradation. Seam failure

single-tier dryer group of a paper

72% of its initial value. This confirms

can occur due to fibrillation of themachine that produced offset andthe performance capabilities ofloops or binder yarns causing a tear incoating base paper at a speed of up

fabrics that are made from SynStronthe seam. The SynStron monofilament

to 1,300 m/min. While the customer(Fig. 1). In addition, a contaminant

is more resistant to fibrillation; thishad previously changed standard

release additive within the

restricts the penetration of chemicals

polyester fabrics every 12 months,

monofilament resulted in the used

and moisture into the monofilamentin contrast the dryer fabric withfabric having 76% of the original air

resulting in a stronger fabric and

SynStron monofilaments achieved apermeability. This provided effective

seam for higher potential life.

use in paper machine fabrics. This

Laboratory test – seam loop load capacity

100
80
60
40
20
0
1
Tending Side

100
80
60
40
20

3

4

5
Drive Side

100
80
60
40
20
0

0
2

Fig. 1: After being used by a customer for446 days, the SynStron dryer fabric stillhad 72% of its original seam strength.

44

120

120

120
Seam loop strength [%]Remaining seam strength [%]

New
Used

Wear test

Abrasion resistance [%]Seam strength proﬁleStandard
PET

SynStron
PET

Fig. 2: High resistance: SynStron can
withstand a substantially larger amount ofenergy before a seam tear.

Standard
PET

SynStron
PET

Fig. 3: In comparison to standard
PET, SynStron achieved, on average,
56% higher abrasion resistance.

32 I 2011 I Voith Paper I twogether

NEW TECHNOLOGIESSynStron monofilament

Standard PET

Fig. 4: The SynStron yarn filament is less prone to fibrillation. In contrast, the standard PET filament (left) has numerous small fibrils after
a sudden break.

In addition, SynStron offers higher

material achieved 56% higher wear

resistance to sudden increases inresistance than standard PET yarns,

fabric tension. These increases areleading to a longer potential life of

normally caused by cylinder wraps

the dryer fabric. Exposure to wear

during tail threading or paper wads

by adverse machine conditions isfollowing a break, causing damage

one of the reasons that dryer fabrics

and removal of the fabric. A SynStronare prematurely removed from thedryer fabric reduces the risk ofmachine. The SynStron fabric hasdamage by absorbing 160% more

greater resistance to the causes ofenergy compared to a standard

wear, such as rough or contaminated

PET fabric (Fig. 2).

roll surfaces, filling materials orcontact with stabilizer seals. This

Increased fabric life due tohelps to achieve cost savings forless abrasion

the paper producer.

A Voith Paper laboratory test clearly

Hydrolysis resistance improves

showed the higher abrasion resistancetear strength

SynStron: summary of advantagest3FTJTUBODFUPGJCSJMMBUJPOt)JHIFSTFBNMPPQTUSFOHUIt(SFBUFSBCSBTJPOSFTJTUBODFt)ZESPMZTJTSFTJTUBODF
t$MFBOFSSVOOJOHSynStron yarns are used exclusively in dryer
fabrics from Voith Paper (PrintTech-S andMultiTech-S). They are available worldwide
as of mid 2011.

Contact
Jiew Poh Liew
jiewpoh.liew@voith.com

of the SynStron yarn (Fig. 3). The
Heat and moisture in the dryer
section are the most difficult
Laboratory test – hydrolysis resistanceenvironmental conditions imaginable

Remaining tensile strength [%]for polyester. Their combined
SynStron
Competitor
Standard PET
100effect weakens standard PET and
ultimately leads to failure of thematerial. Again, SynStron80

monofilaments out perform standard

60

PET. In laboratory tests, degradation40

can be accelerated in order to20

simulate paper machine conditions
over the life of a fabric. After 63 hours

0
0 10 20 30 40 50 60 70
Time [h]exposure to saturated steam at
140ºC, the standard material had
degraded. In contrast, SynStron

Fig. 5: While standard PET filaments havealready torn, after 63 hours in a laboratory
test, SynStron still has 60% of its originaltear strength.

32 I 2011 I Voith Paper I twogether

had retained 60% of its original tearstrength to confirm its superior
performance (Fig. 5).

45

NEW TECHNOLOGIES

Fig. 1: A Voith technician installs
and tests the Voith LSC TecoScan
system in the factory.

Voith LSC TecoSens for tissue manufacture

Sensor measures fiber weight and moisture
without radioactive source
For safety and cost reasons, a major objective of the paper industry has been to measure moistureand fiber weight without using radioactive beams. Using the Voith LSC TecoSens sensor this is now
possible for tissue production.
Currently, online basis weight intissue web simultaneously using athrough the tissue paper is measured

tissue manufacturing is usually

modular sensor unit integrated into

at appropriate locations in the NIR

measured with radiometric basis

the quality control system. The

wavelength spectrum. Simplified,weight sensors. Using radioactive

measuring process used is based

the basic principle is as follows:beta rays, the basis weight of theon infrared spectroscopic methods

The higher the moisture or fiber

tissue web is determined in units

and is particularly suited to tissue

weight, the less infrared light canof g/m². Although this technology

manufacture, which uses fibers

penetrate the tissue material at thehas long been proven, paper

only and no fillers. This method iscorresponding wavelengths. The

manufacturers were neverthelesssuperior to conventional radiometricmeasuring system features a very

seeking a reliable alternative

measurement in both ecological andgood signal-to-noise ratio, enabling

without radiometry.

economic terms.

a high measuring resolution.

With the Voith LSC TecoSens, for

Not sensitive to dirt

The sensor is part of the Voith LSC

the first time a new infrared optical

TecoScan measuring system, which

sensor is now available for tissue

The characteristic absorption bands

has been specially designed to

manufacture that uses one unit toin the NIR optical wavelength range

meet the requirements of tissue

measure both the moisture and fiber

are used to measure the fiber weight

manufacturers. It can be integrated

weight. It measures these twoand moisture of the tissue web. The

completely into Voith’s quality andphysical measuring variables of thedegree of penetration of the lightprocess control systems.

46

32 I 2011 I Voith Paper I twogether

0.45

20

0.41

19
Dry weight [g/m2]

Transmission [%]NEW TECHNOLOGIES

0.37
0.33
0.29
0.25
1,200

18
17
16
15

1,400

Reference value

1,600
1,800
Wavelength [mm]
Water

2,000

2,200

Fiber

DataboxPromethium source based dry weight proﬁleFig. 2: NIR (transmission) spectrum with the measuring
wavelengths used in TecoSens.

IR ﬁber dry weight proﬁleFig. 3: Comparison of mean values (reel) derived from a
conventional radiometric measurement and using
Voith LSC TecoSens.

When developing the measuring

sensor were compared with asystems. Furthermore, the signal-to-system, particular attention was paid

Voith LSC TecoSens that wasnoise ratio remains constant over theto making it non-sensitive to dirt,

installed at the same time. In

entire service life of the sensor andan important criterion especially in

addition, a comparison was madedoes not gradually dissipate as istissue manufacture. The system is

between the reel mean value profiles

usually the case with radioactive

fitted with integrated cleaning nozzlesof the promethium sensor and thesources.

that periodically remove from theVoith LSC TecoSens (Fig. 3).

measuring gap any fiber residues

Both comparisons indicate an

and other contaminants that haveexcellent measuring consistency,

accumulated. This guarantees highimpressive testimony to the accuracy

availability without extra cost andof the Voith LSC TecoSens. Thiseffort for cleaning.

means that it can replace a
conventional radiometric sensor

Voith LSC TecoSens is pre-calibrated

without having to make any

in the factory before delivery. This

concessions.

means that the measuring system
can be used immediately after

Fewer regulations, more safetycommissioning and delivers accurate
and reliable measured values without

Compared with conventional

the need for time-consuming

radiometric measurement, thecorrelations.

Voith LSC TecoSens offers theuser numerous advantages: As all

Comparison confirms accuracy

the statutory regulations forradiometric measuring systems do

A direct comparison between a

not apply, there is far less cost andVoith LSC TecoSens and conventional

effort involved for the company. In

radiometric sensor confirms the

addition, not using radiation improves

accuracy and quality of the newworkplace safety for operating

measuring system. In a test overpersonnel. It is much easier and lessseveral weeks, the basis weight

expensive to replace the infrared

trends (oven-dry) of a conventional

beam in the Voith LSC TecoSens thanpromethium source basis weight

when using radiometric measuring

32 I 2011 I Voith Paper I twogether>>> Info: Sensor measuring principle
Fig. 2 shows the transmission spectrum in the
NIR optical range by way of example for atissue paper. The light transmission is recordedon the characteristic absorption and reference
wavelengths using “same spot” technology,i.e., the individual optical transmission
measuring values come from the same
geometric measuring spot on the paper web
moving under the sensor. This eliminatesinterference caused by measuring
the individual signals from different points
on the paper web. The result is a much better
signal-to-noise ratio of the measurement
and thus a visibly higher measuring resolution.
In conjunction with proven measuring models,the fiber weight and moisture of the tissue
web can be measured accurately without using
radiometric sensors.

Contact
Thomas Ischdonat
thomas.ischdonat@voith.com

47

NEW TECHNOLOGIESDuoFormer D II impresses thanks to extended application limits

Market leader further improved
After more than 230 installations, the DuoFormer D is the market leader and most successful hybrid
former in the world. It provides superior paper quality and stable operating behavior for graphic
paper grades as well as board and packaging paper. In the development process of this former, theparticular focus was on maintaining the existing benefits of the design while achieving a substantial
increase in production capacities.

The improved DuoFormer D II

blades. The combination of flexible

In the case of wood-free paper, theensures stable sheet formation at

inlet zone and curved forming zone

DuoFormer D II extends the available

maximum speeds. Thanks to thein the DuoFormer D II allows

speed range by a considerable

proven flexible inlet zone with threesubstantially faster speeds andamount upwards (Fig. 3). For

flexible loadable inlet blades, the top

higher production rates.

example, the production speed

wire and the surface of thefor a typical 80 g/m² copy paper

suspension are merged gently. The

New applications for board andcan be increased from its previous

advantage over stationary, curved

copy paper machines

1,350 m/min to 1,600 m/min. The

inlet elements is that dewatering

typical sheet structure for thepressures are lower and can be better

Thanks to the extended range of

DuoFormer D, i.e., soft formation

adapted to requirements. This allows

applications for the DuoFormer D II,

and comparably low MD/CD tensile

the formation of the top initial fiber

board machines with a basis weightratio, has been maintained in themat to be controlled in a systematicof more than 400 g/m² and an

upgraded version.

way.

operating speed of up to 1,200 m/min
can be designed as a three-ply

In addition, the dewatering section

In the area of the top wire suction

machine (Fig. 2). The DuoFormer D II

from the forming board to transfer tobox, the DuoFormer D II, unlike thecan increase production rates for thethe press section has been optimized

previous model, has a curved wire

middle ply by up to 30%.

regarding an energy efficient dryness

guide from the start. This stabilizes
the wire run at high speeds without
having to load the forming blades.
This therefore allows the functions

Fig. 1: Location of forming zone for various basis weights.

of wire guiding and forming to be
separated. Depending on basis
weight, more or fewer forming strips
can be used (Fig. 1).

Forming zone:
40 g/m²: Forming strips 3-4
80 g/m²: Forming strips 3-6
120 g/m²: Forming strips 3-8

In the case of low basis weights, thedewatering in the twin wire section iscompleted quickly. The main formingzone is therefore located around the

1

2

3

4

5

6

7

8

first forming blades. In the case ofhigh basis weights, on the other
hand, the forming zone extends tothe back section of the forming48

32 I 2011 I Voith Paper I twogether

NEW TECHNOLOGIES

increase. Drainage boxes are fitted,
tailored to the paper grades
produced. Furthermore, instead ofa suction couch roll, a high vacuum
suction box is used as the last
dewatering element. The first fullscale installation confirms that thisFig. 2: Multi-ply concept with DuoFormer D II.

results in considerably lower
investment costs and also reduced
energy consumption.
Listening to market demands
The further development of theproven DuoFormer D takes into
account current market
developments in board andpackaging paper machines and inwood-free graphic paper machines.

Fig. 3: DuoFormer D II for wood-free paper with extended speed range.

Until now, board and packaging
papers have normally been produced
as multi-ply products on wiresections with several Fourdriniers.

In the wood-free graphic paper

There are two trends on the market

segment, a wide range of basis

for this machine concept: On the one

weights is generally produced on ahand, projects for new board

paper machine. Experience hasmachines are being designed forshown that in this kind of application

operating speeds at up to 30%

the control of the sheet formation isabove the previous typical levels. On

substantially more flexible using thethe other, the number of Fourdriniers

DuoFormer D than when a gap former

is being reduced from five to four oris employed. Thanks to theeven three, in order to cut the

improvements to the DuoFormer D,

specific investment costs. As theit is now possible to benefit from abasis weight of the end product is to

more flexible sheet formation at

be maintained, more pulp has to behigher speeds than before. At the

dewatered in the intermediate ply,same time, this reduces the specificwhich is usually equipped with ainvestment costs. Furthermore, whenhybrid former. This market trend

upgrading the design, consideration

demands a hybrid former that can

was given to achieving as low as

produce a substantially higher ply

possible specific energy consumption

weight at a higher speed.

for the former.

32 I 2011 I Voith Paper I twogether

Contact
Volker Schmidt-Rohrvolker.schmidt-rohr@voith.com

Juergen Prössl
juergen.proessl@voith.com

49

NEW TECHNOLOGIES

Fig. 1: An optimum spreading effect is achieved
with its continuous bow.

CarboStretch can do much more than conventional rolls

Spreader roll reinvented
The operating principle of a CarboStretch roll is simple: solid on the inside, flexible on the outside.
Thanks to this sophisticated solution, the conventional spreader roll has been reinvented – and now
comes with continuous bow adjustment.

The principle of the CarboStretch

The CarboStretch roll stays muchby means of a multi-ring bearing at

spreader roll is based on a solid innercleaner and is more operationallyboth ends of the roll. The direction andtube and a flexible outer tube, bothreliable than its predecessors. Thanks

height of the bow can be selected asof composite fiber material. The inner

to the continuous outer tube over therequired, allowing the spreading effecttube is highly rigid and functions as

entire width, there are no joins where

to be adapted to any operatinga supporting structure. The outerdirt can accumulate or roller bearings

situation. Thanks to the multi-ringtube, on the other hand, is flexiblethat tend to overheat.

bearing, the bow direction on tenderand is curved over its entire lengthand drive side can also be adjusted

in an almost uniform bow. This very

At last – continuously variable

separately. This allows adjustment ofprecise curvature, resulting from thebow adjustment

the spreader effect to optimize thecomposite material and an intelligent

50

web tension profile in cross-machine

bow adjustment mechanism,

One of the advantages of CarboStretch

direction. If the draw is somewhat

produces an optimum spreader effectis the continuously variable adjustment

asymmetrical, it can be correctedin the web in cross-machine direction.

of bow height and direction, achieved

using this spreader roll.

32 I 2011 I Voith Paper I twogether

NEW TECHNOLOGIES

Fig. 2: The second CarboStretch has been running perfectly since commissioning.

Thanks to the modular design, thebow height and direction can also be
adjusted remotely in the future to“Although heading in a completely new technological direction
with the CarboStretch roll, this project has demonstrated whatmeet customer requirements.

motivated partners are capable of achieving.”
Heinz Pall, Head of Coating at Sappi Gratkorn, Austria

The CD temperature and tension
profile is improved thanks to theclever design: The roll is notsegmented, nor are there any heat-

The roll is lubricated either with oil orcover (e.g. AironGuide) is available.

inducing roller bearings from thegrease. At high machine speeds, oil is

For higher machine speeds or non-

CarboStretch coming into contact

generally used, as the maximum

permeable papers, Voith offers awith the paper. This is particularly

speed for grease lubrication of thespecial grooved cover design toimportant for delicate paper grades

roller bearing has been reached.

eliminate the air cushion between

such as coated paper, and during
the smoothing process.

paper web and roll.
Various surface qualities
possibleEasy-to-maintain design

minimal external forces. As the highAs a coating specialist, Voith Paper

In particular, the fact that thecurvature forces are absorbed within

can provide the roll with special

CarboStretch does not have any

the roll itself, it is not usually

surface qualities depending onroller bearings inside the roll tube

necessary to provide the machine

application. For maximum abrasion

makes it easy and inexpensive toframe with additional reinforcement.

resistance, a fiber-plastic composite

maintain. The adjusting mechanism

The new spreader roll produces only

32 I 2011 I Voith Paper I twogether

51

Fig. 4: The newly developed eccentric bearing is the centerpiece of the CarboStretch.

Fig. 3: Heinz Pall is Head of Coating at
Sappi Gratkorn.

However, the complicated design

confidence in the new technology

with a large number of segments, theand installed the second roll directly

associated risk of downtime andin coater 9. There, a breakdown

related high maintenance costs led

would have had much more serious

Sappi to consider other options.

consequences for the production line
than in the calender. But here too,

is located at the roll ends and is

What motivated partners caneverything ran smoothly. “The launchreadily accessible for maintenance.

achieveof the CarboStretch in coater 9 was

The CarboStretch does not havea model start. The bow, jointly

to be taken to a service center to“We were very keen to carry out thedetermined beforehand by Sappi

have the bearings changed and is

project with a competent machine

and Voith, was correct. Likewise,characterized by high operational

vendor. After many discussions withthe alignment of the bow line led

reliability and low maintenance costs.

Voith’s highly motivated young teamto a completely problem-free– backed by a number of ‘old hands’commissioning of the roll. The

CarboStretch rolls can be used in the– we decided to install the first roll intechnology allows separate

coater, calender or winder. The

the calender of production line 9,”adjustment of tender and drive sides

possibility of using it in the press

says Heinz Pall. He continues:– offering even more potential tosection is currently being tested.

“The decision to opt for the calenderinfluence the web run,” reports Pall.

The two initial field tests are being

was initially a way of minimizing risk,

carried out in Austria, in production

as we were moving into completely

The two years of operating experienceline 9 at Sappi Gratkorn where, in

new technological territory. We

have convinced Heinz Pall. He sees a

March 2009, the first CarboStretch

reasoned that this was where we

multitude of application options for

was installed upstream of the winder

could easily cope with any

the CarboStretch: “Installing it in thein the calender, and in January 2010,

operational interruptions.”

press section would be for me thea second unit was installed in thecoater.

next logical step.”
However, even the very first
CarboStretch roll ran according to

52“In principle we were not dissatisfied

expectations. The experience fromwith our segmented spreader rolls

calender operation was incorporated

and are, of course, still using a large

into the design of the second

number of them,” explains Heinz Pall,

prototype. On the basis of the results

Head of Coating at Sappi Gratkorn.

obtained so far, Sappi then showed

Contact
Sebastian Dienst
sebastian.dienst@voith.com

32 I 2011 I Voith Paper I twogether

NEW TECHNOLOGIESNew rubber roll covers for the press section

Increased service life through longer
grinding intervals and high reliability
In order to prevent unplanned shutdowns due to overloading of the roll covers in the press section,
Voith Paper has developed new polymer matrix compounds. The MajorPress, MajorFlow, MegaPress
and MegaFlow rubber roll covers, available summer 2011, have this unique bonding layer that ensures
an extremely high level of reliability. The MegaPress and MegaFlow covers are also equipped with afurther-developed rubber polymer in the functional layer that offers less abrasion, better dewateringand the highest running times.

For papermakers, it is unfortunately a

The innovative polymer matrix was

highest load level in the test stand, afamiliar problem: An overload due tosubject to numerous destruction tests

completely homogeneous failurecontaminants, lumps of dirt and paperin the laboratory. For this reason it ispattern can be detected in theor skewing in the press area can leadcalled Secure Technology. On the rollfunctional layer. Secure Technology

to damages on the roll covers. In thetest stands, rubber roll covers built up

has withstood this massive overload

worst case, failure of the rubber rollin such a way had no failures with awithout damage.

cover and thus shutdowns of the paper

level 6 nip load, in contrast to

machine are the result.

prevalent covers (Fig. 1). Only with a

Bonding layer three times as

nip load from 10, which corresponds

resilient

In order to prevent such unplanned

to 100% massive overload in the

stoppages of the paper machinepress section, did detachments andIn order to further verify the bonding

because of tears in the functional

thus failure of the roll cover occur. If

stability, Voith Paper engineers

layer and detachment of the press

the roll covers are operated up to thisdeveloped another test procedureroll covers from the roll, Voith Paper
has technologically modified the
manufacturing process for its rubberroll covers. Specifically, the polymer
matrix of the base layer and theHigher limit of MegaPress
with Secure Technology

intermediate layer were changed,with the rubber roll covers built up

12

Unmatched reliability
Modification of the polymer matrix
has the advantage of providing
substantially more contact points
between and within the individual
layers. The adhesion and bonding
forces are thus increased. This
ensures a safeguard against failurethat so far is unmatched.

32 I 2011 I Voith Paper I twogether

Index nip loadin three layers.

Improved limit of MajorPress
with Secure Technology

108Limit of standard rubber cover

6
4
2

1

2

3

4

5
6
Speed level

7

8

9

10

Fig. 1: The roll covers equipped with Secure Technology withstand noticeably higher nip
loads than comparable rubber roll covers.

53

NEW TECHNOLOGIES

called the crowbar test (Fig. 2).

Secure Technology did not fail until

Starting this summer, there will

A load at selected points was applied

approximately 6,000 N.

be a total of four new rubber rollhere to the bonding layer in the

covers for the press section.

rubber roll cover with a kind of

In addition to the laboratory tests,

All of them have Secure Technology

crowbar. This test simulates the

Secure Technology was also tested

but can be used for various rollshearing forces appearing in theon paper machines. The new covers

types. The MajorPress andcover when used in a paper machine.

achieved another secured running

MegaPress covers were developed

period without problems (Fig. 4). In

for press rolls and long nip style

Conventional rubber roll covers andaddition, Secure Technology allows

press rolls (jumbo). MajorFlow

covers with Secure Technology werea higher line load. Depending on

and MegaFlow are ideally suited

again compared with one another.

the paper grade produced, thisfor suction press rolls. The new

The conventional roll covers werealso facilitates more dewatering.

rubber roll covers are an

already destroyed at 1,950 N,

Positive consequence: lower energy

inexpensive alternative towhereas the covers equipped with

consumption in the dryer section.

polyurethane covers.

Fig. 2: A load at selected points is
applied to a bonding layer in thecrowbar test. This test simulates theshearing forces appearing in the rubber
cover when used in a paper machine.

MajorFlow

MegaPress

Fig. 3: Major and Mega roll covers withdifferent surface qualities.

54

32 I 2011 I Voith Paper I twogether

NEW TECHNOLOGIES

Coverfailure100

Coverfailure
92 90

88 90

Plant
shut down
90 88

Achievable line loads
Impact resistance

99

100 %

Damage resistance

80 %
60 %

50

0

42

Safety andrunning properties

20 %
0%

Aging/After hardening

Mechanicalproperties
Cover 1MegaPress/MegaFlow
with Secure Technology

35

Cover 2MajorPress

Bonding strength

Fig. 4: The new rubber roll covers Major andMega achieve longer running times in operation
without problems.

Major and Mega – depending on

Abrasion resistance• Outstanding stability• Resilient surface qualities

Secure Technology and an adapted(stable hole volume)

functional layer in which blind drilled• Best nip dewateringholes can be implemented 1 mmdeeper – this results from theincreased adhesive strength of the
3-layer structure. Deeper blind

Without Secure Technology

The advantages of Mega covers are:operating conditions
MajorPress and MajorFlow have

MajorPress/MajorFlow
with Secure Technology

Fig. 5: Comparing the characteristics of the new Mega covers to Major andstandard rubber covers shows impressively that the development goal of extending
the service life was achieved.

• Excellent mechanical characteristics• Outstanding wear resistance• Low heat development for reduced
aging and less wear

Volume lost [%]Time [24h]40 %Running times

126Standard
rubber cover

MajorPress
MajorFlow

2
MegaPress
MegaFlow

Fig. 6: Comparing the abrasion behaviorof various rubber qualities.

drilled holes allow another regrindingof the roll cover. This means that the

Altogether, these characteristics

usable functional layer of the roll coverlead to longer running times andis increased by 25%, and thean extension of the grinding intervals,

dewatering performance increases.

and this results in lower grinding

Contact
Martin Löbl
martin.loebl@voith.com

costs. Also, the usable functional layer
Conventional rubber roll covers

is not reduced by additional grinding

show heavy abrasion or signs ofprocedures. The open surface can bewear under the harshest operating

increased from approximately 28%

conditions. In this case, MegaPress

with the Major covers to 35% with theand MegaFlow are the right choice. In

Mega covers. This also brings about

addition to Secure Technology, theseincreased dewatering performanceroll covers have a newly developedand energy reduction. Along withfunctional layer that consists of an

Secure Technology, the Mega covers

improved rubber polymer matrix.

offer even more reliability, making

The clear development goal here

unplanned stoppages due to external

was to extend the service life

overload a thing of the past.

during critical and high-stress
operation.

32 I 2011 I Voith Paper I twogether

55

NEW TECHNOLOGIES

Fig. 1: Glass fibers are non-aging, flexible, weather resistant, chemically resistant and non-flammable.

Fig. 2: NipVision can be
integrated into all roll covers,
regardless of material or
surface quality.

NipVision – for nip measurements while the paper machine is running

Making the invisible visible
The exact processes in a nip cannot be detected when a paper machine is running and until now also
could not be measured. However, these processes are extremely important for producing high-quality
paper. This is exactly where NipVision comes into play. Glass fibers embedded in roll covers makethe invisible visible for the very first time and thus measurable as well.
The glass fibers allow online

important for paper quality.

Depending on the cover material

measurement of nip conditions

Misalignments and over or under

and the area where the roll is used,while the paper machine is running.

load of one or two rolls are directly

glass fibers are embedded at

The fibers are very sensitive anddetected with NipVision, and avarious depths in the roll cover.

can be integrated in the roll covers

multitude of resulting problems

Due to the specific arrangement

to whatever depth is desired,are prevented. Examples include:of the fibers, the processes in the
nip are shown simultaneously andregardless of their material or
surface quality. In contrast tot Paper web breaks

synchronously. This is a definite

piezo-sensors with whicht Production interruptiont Quality problems
t Unplanned paper machineadvantage compared to piezo-

researchers have experimented
so far, the glass fibers can also
be used in the wet section of thepaper machine, which is so56

downtimest Detachment of roll coversensors, which are arranged aroundthe roll in spiral form and thus do
not pass the nip simultaneously.
Due to the lack of synchronization,

32 I 2011 I Voith Paper I twogether

NEW TECHNOLOGIES

the interpretation of the data is

supplies NipVision with power evenpiezo-sensors are not sufficiently

noticeably more difficult.

during a machine stoppage.

sensitive. Furthermore, due toContinuous data flow

The thickness of the roll coverapplications in the wet area of thecontinuous corrosion problems,does not have to be changed due topaper machine were not possible.

The data obtained with NipVision is

the thin glass fibers. The glass fibers

Therefore, development projects

wirelessly transmitted to a computer

do not interfere with the structure ofusing piezo-sensors were neverequipped with customized software.

the roll, so that detachment of theconcluded in the form of a

The effect of setting changes oncover in the area of the sensor ismarketable product.

the paper machine can be checkedalmost impossible.

live and if necessary corrected.
However, NipVision does not just

NipVision, by contrast, has alreadySuccessful applicationstransmit information regarding the

been tested very successfully on theVoith test paper machine at the Paper

nip pressure, but also information

Until recently, nip measurements

Technology Center in Heidenheim.

about the roll cover itself. The

could only be taken during a machine

The first tests at customers’ locations

continuous temperature

stoppage. A very experienced engineer

started during March 2011 in themeasurements improve safety by

was needed to analyze the results.

Pacific region. From the verygiving an early warning about

The consequences of setting changes

beginning, NipVision has reliably

possible roll cover problems, so thatthat were undertaken on the basisdelivered valuable data for thesesudden roll cover failures due toof the results could only be checked

applications and since then has

cover detachment are minimized.

later, while the paper machine wasbeen continuously available to therunning.

papermaker. The launch to all

NipVision is wirelessly andcustomers is scheduled for the lastcontinuously supplied with power,

So as to facilitate nip measurements

and is always available and does noteven while the paper machine ishave to be pre-activated. Valuable

running, since the early 1990s

knowledge can thus be immediately

development engineers haveobtained, particularly with changes

repeatedly tried to integrate

in the ongoing paper production

piezo-sensors in the roll covers.

process. An intelligent storage

Unfortunately the results obtained

facility attached in the enclosure

were not satisfactory, since thequarter of 2011.

NipVision can …
… be embedded in the following roll cover materials:
rubber, polyurethane and fiber-reinforced composite.
… be integrated in the following surface qualities:
plain, grooved, blind drilled, grooved and blind drilled.

Contact
Dr. Matthias W. Schmitt
matthias.schmitt@voith.com

Peter Schultz
peter.schultz@voith.com

Fig. 3: A schematic diagram of the NipVision sensors.

32 I 2011 I Voith Paper I twogether

57

SPOTLIGHT: WASTEWATER, SLUDGE, REJECTS

58

32 I 2011 I Voith Paper I twogether

SPOTLIGHT: WASTEWATER, SLUDGE, REJECTS

Wastewater, sludge, rejects –On track to maximize waste potential

32 I 2011 I Voith Paper I twogether

59SPOTLIGHT: WASTEWATER, SLUDGE, REJECTS

Converting sludge into valuable minerals and energy

Greater added value thanks to CTC technology
The hallmarks of modern Voith designs for paper mills are integrated and environmentally compatible
processes with a high level of economic efficiency. The latest approach in this area is CTC technology:
a process for converting paper sludge to valuable mineral products and thermal energy. This has
allowed both high-cost waste disposal and energy consumption to be minimized.

Fig. 1: CTC technology is
an important part of theIntegrated EcoMill.

Recovered paper processing currently

even used as mineral fertilizers in

into reactive minerals and thermal

produces more than 25 million metricagriculture, today it is mainly

energy. CTC stands for “Controlled

tons of paper sludge waste worldwide.

combusted in power plants with

Thermal Conversion.” The minerals

This is an increasing trend, as recycled

fluidized bed technology and therefore

produced under controlled conditions

fibers are being used more and moreproduces steam and/or electricity.

have a large reactive surface and are

and for increasingly high-quality

However, the resulting calorific value

ideal, for example, as hydraulicpapers. This puts stringent demands

is very low. In addition, about 25% ofbinders in various industries, e.g. foron fiber quality that can only be

the sludge used occurs as ash, which

producing cement-like substances.

achieved by means of a higher rejectin turn results in disposal costs.

CTC technology therefore produces asaleable product from the sludge

rate in the treatment process. The
result: more paper sludge.

CTC adds more value to sludge

occurring. It also yields electricity
and steam, which can be used in the

Whereas previously large volumes ofUsing CTC technology, it is now

sludge ended up in landfill or werepossible to convert the paper sludge

60

paper mill.

32 I 2011 I Voith Paper I twogether

SPOTLIGHT: WASTEWATER, SLUDGE, REJECTSThe amount of waste material to be

Feasibility study

disposed of, and thus the disposal
costs, are substantially reduced.

To be able to illustrate the specific

The other 50% is made up largely

economic and ecological advantagesof calcium carbonate and kaolin.

CTC technology is another key

of a CTC plant, we will use thecomponent of Voith Paper’s Integrated

practical example of a newsprint

As a result of the sludge conversion

EcoMill (IEM), a cost-efficient andmill.

process in the CTC plant, the182,000 t of paper sludge yieldenvironmentally compatible paper
mill (Fig. 1). The technology was

The paper mill has a production line

annually around 49,000 t of reactive

developed by experts from thefor 436,000 t/year of newsprint paper

minerals, 16,000 MWh electrical

Dutch MinPlus-CDEM Group, whichfrom 100% secondary fibers. This

energy and 140,000 t steam used

specializes in sludge recycling. In

requires around 558,000 t/year offor paper manufacture and to relieve

January 2011, Voith Paper acquired

recovered paper, which is prepared

the load on the steam boiler. The

the technology including patents.

in the plant’s own de-inking facility.

transport and disposal costs for the

Using a “full scale” pilot plant with a

As a result, the plant produces

sludge are dispensed with in theircapacity of up to 200,000 t/year, thearound 182,000 t/year of paper

entirety.

process was refined and developed

sludge and 25,000 t/year in rejects.

to industrial maturity. Since 2007,

There is no power plant on site.

The investment costs for the plantsludge from several paper mills has

Electricity is bought from the grid,

described are in the range ofbeen processed in the pilot plant.

and the necessary process steam is25-30 million euros, depending on

The CTC process has proven effective

produced by steam boilers. The

scope of supply. As the CTC plantand has been extremely stable.

rejects are sold.

substantially reduces or even

The minerals extracted are

In the CTC plant, screw presses

costs, return on investment times

substantially more reactive

increase the solids content of theof between four and six years are

sludge to more than 50%. This solid

achieved. This does not takeIn the CTC process, combustion inmaterial in turn is composed of 50%

account of possible subsidies or

the fluidized bed takes place underorganic fines and fibers combined.

CO2 credits.

eliminates energy and disposal

controlled conditions at exactly thepredefined combustion temperature.
In the process, the minerals contained

Fig. 2: The return on investment time of a CTC plant is between four and six years.

in the sludge are dehydrated. Kaolin
is converted to metakaolin, which ismuch more reactive. Part of the
carbonate is extracted from thecalcium carbonate. This corresponds

Recovered paper

Paper millPaper

558,000 t/year

436,000 t/year

Production line

to the process of lime or cementburning (calcining).
Sludge182,000 t/year

Electricity
16,000 MWh/year

Steam
140,000 t/year

The minerals produced in this way
have high pozzolanic characteristics,

CTC planti.e., inclined to react with water andcalcium to form a solid structure.
Rejects
25,000 t/year

Minerals
49,000 t/year

They are therefore suitable for adding
to cement as they improve the binding

32 I 2011 I Voith Paper I twogether

61

SPOTLIGHT: WASTEWATER, SLUDGE, REJECTS

Reference plants allow
customization
Voith Paper offers CTC plants
worldwide. To this end, reference
sizes were developed that can beadapted to the customer’s individual
needs. The largest plants process
up to 200,000 t sludge per year.
The smallest is designed for around50,000 t, making it ideal for smaller
and medium sized mills.
Figs. 3 and 4: In Duiven, Netherlands, 200,000 t/year of paper sludge are converted
into reactive minerals.

As a module of the Integrated EcoMill,CTC technology helps to sustainably
improve the overall ecological balanceand strength properties offrom several paper mills to produceof a paper mill. However, far moreconventional cement. Other fields

over 50,000 t of reactive minerals.

often a CTC plant is suitable forof application are adsorption

As this is an exothermic process,retrofits to existing paper mills. With

processes in the liquid and gaseous

more than 6 MW of electricity arethis in mind, Voith has developed aphase, for example in the binding ofproduced at the same time using acomplete package in which everything

heavy metals, where the minerals

steam turbine. The specific electricity

is supplied from a single source – fromwith their large reactive surfaces

generation is 120 kWh per metric ton

the preliminary phase through plant

function as sorbents. This coversof sludge.

design and culminating in thecomplete installation andjust two of the known areas ofcommissioning.

application for these reactive

For optimum operation of a CTC

minerals to date. There is theprocess, the sludge composition

potential for further fields ofmust be known. Over the years a lot

Although the investment costs areapplication.

of know-how and experience hashigher than for conventional

been gathered about the effect of

combustion power plants, the revenue

Thanks to the low combustion

sludge composition on combustion

from the minerals makes themtemperature, a major portion of theconditions. The basis of this is aeconomically effective in a very

carbonate is retained and the

database containing data on more

short time. In addition, the ecologicalemissions of the greenhouse gas

than 200 types of sludge from allbalance through the reduction ofcarbon dioxide are reduced. The low

over the world and a speciallycarbon dioxide emissions iscalorific value of the paper sludge isdeveloped measuring procedure forconsiderably improved.

also sufficient to operate the CTC

analyzing sludge composition andprocess without additional fuelcombustion properties.

input.
Interested paper mills can have their
Several years experience inpaper sludge treated at the Voith

pilot plant

Paper pilot plant and have therecovered minerals analyzed withSince 2007, the pilot plant in therespect to their product qualities.

Netherlands has been processing

In addition, the energy obtainable inaround 200,000 t/year of sludge

the process can be established.

62

Contact
Joep Biermann
joep.biermann@voith.com

32 I 2011 I Voith Paper I twogether

SPOTLIGHT: WASTEWATER, SLUDGE, REJECTS

In conversation: the co-developer of CTC technology“The value of the sludge is in the minerals”
Dr. Joep Biermann achieved the breakthrough where others had been researching for years without
success: He is one of the people who developed CTC technology. From the very outset he believedin the potential for sludge recycling – and the results have proven him right. In the meantime, he isbringing his experience and know-how to Voith Paper.

Where are the origins ofhigh level of temperature control is

CTC technology?

necessary to improve the value of theminerals contained in the sludge, as

The technology has been developed

this is the starting material for theover the last fifteen years. We followed

CTC process. This is why we also

the traditional route, starting withopted for fluidized bed firing, as thissmall tests under laboratory conditions

method has the great advantage ofto today’s full-fledged pilot plant, whichallowing the process conditions to be

has been operating for more than fivecontrolled in a targeted manner.

years.
Only if the sludge is treated properly,
What drove you to devote yourself toi.e., thermally converted under thethis issue?

proper, controlled process conditions,will a highly reactive mineral product

The key spur to the development was

result. We therefore clearly defined

the worsening problem of sludge

and patented the spectrum for the

disposal. In the Netherlands in

optimum operating conditions. In

particular, this was becoming more

addition, the thermal process produces

and more difficult and expensive.

energy in the form of steam and/or

Against this backdrop, four Dutchelectricity.

paper mills joined together to develop
a technology to fundamentally resolve

And how do the minerals reach thethis disposal problem and – mostcustomers?

importantly – to do so in a sustainablefashion. It was obvious to us that a

That is not a problem. Voith supports

lasting solution could ensue only on

its customers in this area andthe basis of new value creation.

can provide contacts. Apart from its

Accordingly, we recognized that therole as facilitator, Voith Paper is also

true value of the sludge lies in thedeveloping additional sales markets forminerals it contains.

these mineral products.

Fig. 1: Dr. Joep Biermann’s goal was tofind a sustainable solution to the sludge
disposal problem.

What is the key element in the CTC
process?
The most important factor is controlling
the temperature. That is to say that a

32 I 2011 I Voith Paper I twogether

63

SPOTLIGHT: WASTEWATER, SLUDGE, REJECTS

Fig. 1: Order for a clarification
facility with E2E reactor in Belarus.

New generation of reactors for anaerobic wastewater treatment

Simple reactor concept, high level of performance
The new “effluent to energy” (E2E) reactor bridges a market gap by combining the advantages ofhigh-load technology with those of UASB (upflow anaerobic sludge blanket) reactors. While thesimple design is impressive, it is also clearly more efficient than the UASB reactors still often used.

Anaerobic technology has been usedtechnology can also be used withfor more than 25 years for purifying

medium loaded types of wastewater.

industrial wastewater. The

An essential requirement in theconventional UASB reactor is thedevelopment of the E2E reactor was

most well-known product. It is still

retention of the simple and ruggedvery prevalent even today, but has adesign that conventional reactors

decisive disadvantage: its low

have.

specific loading capacity. Modern
high-load technology provides a

Impressively simple technology

100
95
90
85
80
75
70
65
60
55
50

E2E reactor

UASB reactor
0

solution here. After successfully
applying the R2S reactor for highly

Like the UASB reactor, the E2E

loaded or calcium-rich wastewater,

reactor also consists of a closed

Voith Paper engineers developed thecylindrical flat-bottom tank. The tank

new E2E reactor line. Thus high-load

can be made of steel, concrete or64

COD degree of degradation [%]It also offers extremely robust operation.

5

10

15

20

25

30

Speciﬁc volume load in kg COD intake
per m3 and day
Fig. 2: Comparison of a UASB reactor with
Voith E2E reactor.

32 I 2011 I Voith Paper I twogether

SPOTLIGHT: WASTEWATER, SLUDGE, REJECTS

glass fiber reinforced plastic. Therefrom graphic paper mills on a DIP

was chosen so that the unit canare three phase separating units,basis, TMP wastewater or bleachingsignificantly disburden thesimply called separators, in the upper

plant wastewater and condensates

clarification facilities present inpart of the tank.

originating from pulp production.

many operations, or so that load-

By means of a specially developed

To demonstrate the capability oflamella configuration in thethe E2E reactor under industrial

separators, the biogas is removed atconditions, the smallest reactor

Even outside the paper industry, thefirst. After this, anaerobic sludge

size was produced as a mobile

E2E reactor is of interest for water-

carried along with the draining water

unit and has been in use continuously

intensive industries. Thus, the firstis retained. The decisive advantages

since the end of 2009. Its capacity

customer that Voith installed therelated wastewater costs can benoticeably reduced.

of the E2E reactor, as compared toconventional reactors, are its smaller

Fig. 3: Sectional view of an E2E reactor.

diameter and its higher specificconversion.
Inside the E2E reactor, a recirculation
flow returns the anaerobic sludge tothe high-load zone. Thanks to its
simple design, the E2E reactor fulfills
all important criteria expected fromanaerobic reactors today.
Advantages of the E2E reactor:

t Low tank volume due to high-load
technologyt High hydraulic capacity of
precipitators due to 2-stage
separator conceptt No odor emissions and low profile
appearance due to enclosed designt Easy maintenancet Low investment costs due to highspace-time yield
Usable in many areas
The E2E reactor is designed for
anaerobic pretreatment of industrial
wastewater that contains dissolved
organic contaminants. As with UASB
reactors, it can be used in manybranches of industry. In the area of
paper manufacturing, it is usedprimarily for purifying wastewater

32 I 2011 I Voith Paper I twogether

65

SPOTLIGHT: WASTEWATER, SLUDGE, REJECTS

local clarification facility, thethe system achieved efficiency

customer was able to noticeably

factors of over 80% within the

reduce its wastewater fees.

shortest time.

Nearly three times the specific

Rebuild brings energy

load

consumption and costs down

In a second installation, the E2E

No less important is the extension

reactor was used at a paper mill inor retrofitting of existing systems

Kaufbeuren, Germany. The paperwith the E2E reactor. Previously,

mill produces around 180 tons offor cost efficiency, wastewater

testliner per day and has its own

with COD loads between 1,500 mg/l

clarification facility, which consists ofand 2,500 mg/l was purified almosta primary treatment, a UASB reactor,

exclusively with aerobic high-load

an activated sludge system and final

stages such as MBBR reactors,

clarification. The E2E reactor waswhich Voith also has in its productloaded with the same wastewater as

portfolio. Today the replacement of

the UASB reactor, so that the twosuch aerobic high-load stages by anreactor types could be directly

anaerobic E2E reactor can definitely

compared with one another.

make sense. In this way, energyintensive blowers are not needed, theThe results were convincing: Whiledegradation rate stays the same or

the approximately 540 m³ UASB

is even better. In addition, biogas isreactor of the paper mill was given

produced that can be used for powera load of about 5.4 t/day, the mere

generation. The accumulation of

70 m3 E2E reactor could handle asludge is likewise noticeably

load of up to 2 t/day. The E2E reactor

reduced, thus ensuring low

reaches a specific load that is more

operating costs.

than 2.8 times that of the UASB
reactor.
Fig. 4: E2E reactor in Kaufbeuren, Germany.

The simple design and highdegradation rate – combined with

The advantages of the E2E

its broad application possibilities –reactor for was an operation of thetechnology were also evident inmake the E2E reactor an important

Nestlé food company in Holland.

the case of a project in Turkey.

component for cost-optimized

Ensuring stable continuous operation

Due to official specifications,operation of wastewater purification

with heavily fluctuating wastewater

installation of an anaerobic

systems.

compositions was the biggest

preliminary treatment stage waschallenge.

required at a company in the candy
industry. Due to the low investment

66

Such fluctuations are characteristic

costs and also the low spaceof the food industry due to therequirement, the company decided

alternation of production andin favor of the E2E reactor. Anothercleaning cycles. The E2E reactor

reason for the decision was themastered this task without any

hermetically sealed design thatproblems. In addition, by discharging

prevents annoying odors in thethe pretreated wastewater into thesurrounding area. After startup,

Contact
Axel Gommel
axel.gommel@voith.com

32 I 2011 I Voith Paper I twogether

SERVICE

Fig. 1: Complete service:
All maintenance tasks become ourlong-term responsibility.

From service provider to integrated service partner

Service contracts ease the load for papermakers
Repair, maintenance and technical optimization: What used to be well-established tasks of a paper
mill are frequently, in today’s competitive atmosphere more of a diversion from actual paper
manufacturing. Voith Paper is thus offering long-term service contracts, with fair collaboration
based on partnership, so that paper mills can concentrate on their core competences ofmanufacturing and sales.

Over the years, Voith Paper has

Maintenance contracts ensure

off here. Operational safety

grown from being a service provider

reliable operations

and reliability are thus monitored

to a complete service partner. The

and ensured. “Execution orcontinuous further development ofIn the first model, Voith Paper

monitoring of specifically developed

service products is characterizedtakes over preventive inspection

inspection and maintenance cycles

by integrating existing service

and maintenance of demanding

is done on the basis of multi-year

potentials and individual adaptation

units and machine sections.

service contracts. This ensures

to meet the respective customer

Mechanical engineering expertise,

the system areas in question run

needs. To utilize the advantages

the most modern measurementsmoothly and reliably,” explainsof a long-term service partnership,and diagnostic tools, and a

Bernd Stibi, Vice President of

paper manufacturers can choose

systematic method of testing

Products & Services Europe at

between several models.

and documentation all pay

Voith Paper.

32 I 2011 I Voith Paper I twogether

67

SERVICE

The necessary reserve and wear

expenditures give the operating

Safeguarded over the entire

parts are included in the maintenancecompany a first idea of the ROI

lifecycle

contract. In addition, Voith is(return on investment) as a decisioncommitted to continuous further

criterion for the other steps.

A lifecycle service contract
establishes a long-term partnershiptraining for its service employees.
Therefore, the paper manufacturer

Such an analysis can extend tofor servicing the paper machine,is relieved from the necessity of

specific system areas and operating

the production line or even the entire

parts procurement and theprocesses or be applied as a multi-

paper mill. Voith Paper takes oversometimes expensive training ofmachine investigation. Voith Paper

the entire technical responsibility.

its own employees.

offers not only machine audits but

This service includes several

also safety, process, quality andelements that are individuallyPartnership contracts uncover

maintenance audits. “Our aim isarranged and adapted, depending

potential

always to issue a report for theon the customer’s needs.

customer indicating which measures
Paper machines are reliably

can attain the formulated goals,”

The contracts regulate the classic

designed. However, the components

Stibi explains.

disciplines for maintaining andincreasing technical system

are continuously developed due
to research findings, improved

If necessary, in a second step,availability. The latter are, formaterials and operational experience.

details of the technical feasibility

example, repair, maintenance andIn addition, paper manufacturersof the measures are investigated

optimization. The paper manufacturer

are exposed to challenges industry-

within the framework of a preliminary

gets support in the form of service

wide, especially regarding the

project. The operator of the

packages for resident maintenancecost-effectiveness of manufacturing

facility then receives a customized

and operational assistance. The

processes. Therefore, the potential

offer with technical specifications,range of services is not restricted

for savings has have to be identified

project schedule and prices.

to Voith’s own delivery. As the central
service provider, the machine areas

and used. Likewise, requirements

68

for safety, environmental protection“We don’t primarily view the audit

and services of other suppliers areand sustainability are constantly

and preliminary project as a basic

also coordinated. Operationalchanging. “Older paper machines

analysis of our own machine

assistance means that experts

almost always have the potential

delivery,” says Stibi. “Rather, wefrom Voith Paper, for example,

for making a decisive contribution.

offer our customers an independent

remain on site over the longterm

For that reason, we are offering

service for decision making. Anotherafter a startup or process

our customers the opportunity tothing that’s new: We supplement

adjustment. They support theutilize this possibility by means

the price for this service with apaper mill’s own personnel inof a multi-stage concept,” says

success-dependent element. In

achieving the paper production

Stibi.

other words, only when the projecttargets for quantity, quality andgoals have been demonstrably

cost-effectiveness. They monitor

First of all, a team of experts

achieved does Voith Paper receive

production and help optimize

performs a systematic audit to

its fair share of the success.” Theoperation of the system in terms

analyze the respective system,

implementation phase follows asof mechanics, process technology

machine or process, looking for any

the third stage. The paper mill canand cost-effectiveness.

improvement. At the same time,always choose to carry out thissuggestions are developed as to howphase itself. However, Voith Paper is

The paper mill is supported inthis potential can best be used.

always available and if necessary will

dealing with the system as long

Evaluation of the target contribution

support implementation ofas necessary – even over several

and estimation of the necessary

previously defined measures.

years, if desired.

32 I 2011 I Voith Paper I twogether

SERVICE

Depending on the service package,

Condition-oriented
Performance
Measurementmonitoring
monitoring

Malfunction-related Time-dependent
Malfunction
Periodicelimination
planningwith the resident service Voith Papertakes care of maintenance, repair andRisk-based
Risk analysis

replacement parts management, as
well as provision of fabrics and roll
Optimization of costs
by combinationof maintenance strategies

covers. The contacts necessary forpaper production are always
are on site whenever necessary. Stibi
explains: “From resource planning toprocurement and logistics of therequired parts, from the paper
machine all the way to building

Maintenance costs

available, and the required specialists

Costs of preventive
maintenance
Availability

management, everything goes
through one contact point connectedto the global Voith network.”

Costs of unplanned
downtimes

Fig. 2: Maintenance can be performed through various strategies. The right combination
lowers costs for the paper manufacturer.

The customer profits from
common interest
The lifecycle contract conceptmeans that payment for services

Voith
process
serviceModernization/rebuild

system – whether it is a matter of
production tons or another

Efﬁciency

is linked to the capability of theProcess optimization

performance figure of technicalavailability. “In the end, the operator

Technical maintenanceVoith
product
serviceof the facility gets a calculable
System’s own wear reservebudget amount for maintenanceand repair. The contract is thus

Startuptransparent and fair. The partnershipbased, long-term common economic

0

1

2

3

5

4

6

7

8

.....

Time [a]interest sets obligations for bothparties,” according to Stibi.

Fig. 3: Voith accompanies the paper mill through the entire lifecycle.

An important building block oflifecycle service is performancesystem. And finally, performance

management. Similar to other service

management is a long-term

contracts, the goal is continuous

optimization process. Along withimprovement of the system overclassic maintenance, these

the entire lifecycle. Stibi summarizes:

three lifecycle building blocks“Operational assistance is support

enable us to ensure that thein the first phase in the lifecycle

requirements for system efficiency

of a paper machine. Resident

are met over the entire lifecycle.”

Contact
Bernd Stibi
bernd.stibi@voith.com

maintenance service maintains
the technical availability of the

32 I 2011 I Voith Paper I twogether

69

FORUM

Sustainability in practice at Voith Paper

Less energy, water and waste worldwide
Innovations from Voith Paper always target configuring customers’ production facilities so that they are
more economical and environmentally friendly. At Voith Paper’s own facilities, it is also a matter ofusing resources as efficiently as possible. Specific measures at locations worldwide have already led
to a significant reduction in CO2 emissions, fresh water usage and a clear reduction of waste.

What began at Voith Paper as a

Corporate Environment at Voith. “Weeffluents and emissions associated withcomplement to certified environmental

want to implement ecological measures

the production processes. Therefore,

management has become veryin a cost-effective way.”

the location is considered holistically.

management. “For us, it’s a question

In order to achieve that, Voith Paper is

Heating and cooling in anof creating economic added value foranalyzing its own production processes

environmentally friendly way

Voith’s energy and resource use, forat several locations worldwide under

example, by closing loops andsustainability aspects. These analyses

Such an analysis of a Voith Paper

implementing efficiency measures,”especially take into account water andlocation in the Chinese city of Kunshan

explains Torsten Kallweit, Head ofenergy usage, as well as waste,

has already led to the first measurable

successful: ecological businessFig. 1: The vacuum distillation system in Heidenheim, Germany,means a reduction of 200 metric tons of emulsion waste per year.

70

Fig. 2 and 3: The combined heat and power plant in Düren, Germany,
produces almost 500 MWh of power per year (top). In addition, consumption of natural gas was reduced by improving pipe insulation (bottom).

FORUM

Fig. 4: Better light, 25% less energy: efficient lighting inWest Monroe, USA.

Fig. 5: The São Paulo, Brazil, location treats more than 60,000 m3 ofeffluents per year.

results. A simple and effectiveat the West Monroe location in thereuse. The loop makes sense bothmeasure takes effect here: Rather

USA were reduced by 115 tons/year.

economically as well as ecologically.

than operating heating and air

The new, more energy-efficientconditioning systems separately withhalogen lighting consumes approx.

Voith Paper found another way tofuel oil and natural gas, both systems

25% less energy with improved

reduce waste in the area of coolants.

now run with natural gas only. Aroundlighting quality.

They are used for grinding and

800 metric tons of CO2 emissions per

drilling on turning and millingyear are therefore reduced due to the

Need for fresh water noticeablymachines, for instance, and havelower CO2 emissions of natural gas. It

reducedto be disposed of in an elaborate

is especially positive that the measure

fashion. In order to reduce thecould be implemented without a

Efficient use of water as a resource

amount of waste, the Heidenheim

large adaptation of the existingalso plays a central role. The best

location relies on a vacuum distillation

heating system.

example of this is the reduced freshsystem. It removes water from thewater required for the production of

coolant so only a fraction has

Voith Paper has also achieved a lot inroll covers at the São Paulo, Brazil,

to be disposed. Approximately 90%

the last few years at the German

location. Here, water is primarilyof water content is filtered out.

location of Düren. Power and heatneeded for cooling and cleaning

Altogether, the total amountare produced there in an especiallyprocesses. By switching to waterof coolant to be disposed canenergy-efficient and low-emission way

from its own water treatment system,

be reduced by about 70%.

by means of power-heat cogeneration

which Voith operates at the location,in its own combined heat and power

the need for fresh water was reduced

As Global Ecological Businessplant. In addition, the insulation of

by over 20%, or by about 8,500 m3.

Manager at Voith, Andreas Mayer

more than 2,000 meters of piping
was improved. Thus consumption ofhas supervised some of the projects
Reducing and preventing waste

natural gas was reduced by approx.

and is satisfied: “The success of ourinitiatives can be clearly measured

30%; in addition, the power generated

Voith Paper also pays special attention

and confirms our methods. And not

is fed into the location’s own grid.

to material efficiency in productjust in the short term.” According

Therefore, about 620 tons of CO2 per

manufacturing so as to reduce

to Mayer, the know-how regarding

year are saved.

waste or, even better, to prevent it

resource-efficient processes available

entirely. Thus the yarns produced

within Voith is used internally for

As to the question of what the energy

in Summerville, USA, for paper

economical and environmentallyis used for at the locations, it turns

machine fabrics are sent to otherfriendly production. Customers also

out that lighting is a substantial

Voith locations almost entirely on

profit from this: The knowledge gained

portion, along with other uses.

reusable yarn reels and special

from this process is used in the

Simply due to a new lighting system

reusable pallets. After being used,

development of even more efficientin the workshop, the CO2 emissions

the empty yarn reels are returned for

products.

32 I 2011 I Voith Paper I twogether

71

FORUM

Two new orders for Voith Hydro

More hydropower for China
Two Chinese power plant operators have just commissioned Voith Hydro to equip their new hydropower
plants. A total of 1,880 MW of clean, renewable energy will come on stream.
To expand the Yantan power plant

Altogether, the two projects will

located in the southern province ofgenerate 1,880 MW of new capacity

Guangxi, China, belonging to thefrom climate-friendly renewable

Datang Yantan Hydro Power

sources. Today, China generates 16%

Company, Voith Hydro will equip twoof its electricity from hydropower.

340 MW units with new generators.

According to government plans, theThe second order was placed byexisting capacity should be expanded

the Huanghe River Hydro Powerby 50% to 300,000 MW by 2020. The

Development Company, which will

use of hydropower enables China tobuild the Yang Qu power plant on the

pursue its goals for economic growth

Yellow River in northwestern China.

and in the process to take climate

For this project, Voith is deliveringand environmental protection into

three Francis turbines with an output

account.

of 400 MW each. The total value ofboth orders is about 40 mio. euros.

Fig. 1: Runner of a Francis turbine.

Voith Industrial Services lets the light shine

Saving energy with LEDs
Where bright light is needed, LEDs offer the best service. No
other lighting system is currently able to produce such a highoutput of light with such low energy consumption and high color
rendering. The Voith Industrial Services corporate division offers
efficient lighting concepts for industry using LED technology.

LEDs (light-emitting diodes) haveand for true color representationhigh energy efficiency: They consumeof illuminated objects. Since the

40 to 80% less power with the same

effective service life of LEDs is longer

or even better light output. That has athan that of conventional light bulbs,

positive effect on energy costs.

maintenance costs are also reduced.

Subsequent disposal of the light

All services – from light planningbulbs is also simple.

and selection of the light bulbs tomounting and maintenance – are

LED lighting technology can be
Fig. 1: Retrofitting with LED lighting
pays off.

72

included in the offer.

used in nearly all areas. It is also
ideal for a pleasant work atmosphere

32 I 2011 I Voith Paper I twogether

FORUM

Precision with Hirth couplings from Voith Turbo

Strong teeth for connecting and accurate positioning
Just imagine: 41,600 Formula 1 race cars reach their average torque of 360 Newton meters at the sametime. Therefore, an unbelievable 15 mio. Nm thus come together. A torque volume with a frequently unappreciated machine component transmits without any strain: the Hirth coupling.

For the most part, it has an

At the end of last year, Voith Turbo

But the Hirth coupling used not only

understated existence. There is hardly

had manufactured its largest turbine

as a connection element for shafts,

a connection element that is morepart so far: The diameter is 1,100 mm

discs, wheels and cranks. It is also a

versatile than the Hirth coupling.

with a weight of 800 kg. The Hirthpositioning element with astonishingTransmitting high torques withcoupling connects the two turbine

accuracy. The deviation is at mostcomparatively small diameters – thatdiscs, which rely on extremely

1-2 angular seconds. With thisis one of its major strengths. Thisaccurate centering with high true-

precision, for example, the little horsemeans Hirth couplings can be foundrunning precision. Were this not

on a children’s merry-go-round within pumps, compressors and fans,the case, damage to the turbine

a diameter of 6 m could be exactly

as well as in milling machines, gears

would be inevitable. The face surfaces

positioned to half a hair’s breadth. In

and turbines. Voith manufacturesof the two discs have conical teeth

practice, accuracy like this is essential

these connection elements, but also

all around. Screws and connecting

in machine tool manufacturing such as

undertakes the complete calculationbolts draw the discs into one anotherrotary indexing tables and tooland design consulting.

in self-centering fashion and thus

carriers, among other areas. Medical

fix them in a positive locking manner.

examination couches and operation

It was just this know-how that was

Each tooth is fully brought to bear.

tables are other applications benefiting

needed in the case of the latest orderThat gives the Hirth coupling thefrom exact positioning and fixing.

from an American turbine manufacturer.

ability to transmit enormous torques.

Fig. 1: Customers get complete
service with the Hirth coupling:
design consultation, calculation,
manufacturing and quality assurance.

73

FORUM

Briefly explained

Lime trap

Anaerobic reactor technology incombination with a lime trap makes
the lime problem manageable.
It enables biologically treated
and decarbonized water to berecirculated into the production
process. This recycling lowers
the average water consumption in
paper production.

Did youknow?

Briefly reported

Queen in King’s Lynn
In February 2011, Queen Elizabeth II and Prince Philip visited Palm Paper’s mill inKing’s Lynn, England. The paper machine delivered by Voith is the widest fornewsprint worldwide and produces 400,000 metric tons/year.

twogether cultural tip

Cider, spring rolls and art

Voith is publishing its ﬁrst
sustainability report in 2011.
For more information, visit:www.voith.com.

Conundrum
cornerPut these scrambled lettersin the right order to get four
technical terms from the paperindustry.

REDWNIFESRENTCIABEIRACON OTCRERA
NGCRESIEN
Solution:

Manchester is one of the most important economic and cultural
centers of Great Britain and also a place where Voith Paper is located.
In one of Europe’s most multi-cultural cities, spring rolls from Chinatown meet paleo-industrial romanticism and modern architecture.

It’s a lively mix. No wonder the
residents in Manchester live according
to the motto: “Everything is possible.”
Whether it’s the Gothic town hall(see ﬁg.), modern Bridgewater Hallor the 168-meter-high Beetham Tower– the city center with its characteristic
brick buildings can be comfortably
explored on foot. Here, pub culture
with cider and ale meets urban art
and trendy bars, e.g., in the “hip”
Northern Quarter. There is culture in
the Manchester Art Gallery, among
other places, and in M.E.N., Europe’s
largest concert hall. Soccer is playedin the legendary Manchester United
stadium, Old Trafford.

Winder, ScreenFit,
anaerobic reactor, screening74

32 I 2011 I Voith Paper I twogether

FORUM

Briefly queried

Wolfgang Klotzbücher
Area: development of machine controls
Works for Voith Paper in Heidenheim,
Germany, for nearly 25 years.

twogether book tip“The Book of Paper”“The Book of Paper” is part of a book series that researches thecreative potential, characteristics and qualities of seemingly
ordinary materials such as paper, wood, glass and stone.

The works of designer and sculptor Oliver Helfrich and photographer
Antje Peters are shown along with essays by artists, architects andscientists who all have their own special relationship to paper. Fromtissues to takeaway coffee cups and milk cartons, without us even being
aware of it, paper plays a central role in daily life. “The Book of Paper”
develops the aesthetic value of this often ignored material through paper
sculptures.
Title: “The Book of Paper”, ISBN: 9789460830334, hardcover, 48 pages.

Where would you like to spend yournext vacation?
In a sailboat on the Mediterranean.

What do you do to avoid stress?

Briefly Googled“Paper Toss”
The free application “Paper Toss” isa fun game for your smartphone ortablet computer. In this entertaining
game, you throw a paper ball into thepaper basket that is sometimes closer,
sometimes further away. To add difﬁculty,
a fan inﬂuences the direction of the paperball. A totally new kind of waste paper
collection.
Download: http://itunes.apple.com/

32 I 2011 I Voith Paper I twogether

I try to plan my day realisticallyand to always include somethingthat I enjoy. If an urgent job
comes in though, I take it on ina sportsmanlike fashion.

Finally: What advice do you havefor young people?
They should seek informationand guidance from various sourcesand go through life with their eyes
open.

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Voith Paper

Published by:Voith Paper Holding GmbH & Co. KG

Editor:Julia Bachmeier
Corporate Marketing
Voith Paper Holding GmbH & Co. KG
St. Poeltener Strasse 43
89522 Heidenheim, Germany
twogether.voithpaper@voith.com
www.voithpaper.com

Technical editors:
Simone Heinrich
Elisabeth Marton
Helena Pirttilahti-Feichtinger
Nadine Queiser
Verena Witt

Design, layout and typesetting:Beate Hornischer
Corporate Marketing
Voith Paper Holding GmbH & Co. KG

Images:p. 5/58 Shutterstock.com
p. 19
Shutterstock.com
p. 31
Shutterstock.com
p. 56
Shutterstock.com
Other images: Voith Paper archive

Paper:The recycled paper, RecySatin,of this magazine consists ofat least 80% recycled fibers
and was produced on a Voith
paper machine.

July 2011, Issue 32

Id-No. 1111236
www.bvdm-online.de

Copyright 07/2011: Reproduction andcopying only with express approval of
the editor.

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32 I 2011 I Voith Paper I twogether