twogether
Paper Technology Journal

31

Integrated EcoMill relies on complete process integration I Hainan:largest paper machine in the world I First Curtain Coater for board

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 ofthe Voith GmbH Management Board
and President Voith Paper.

31 I 2010 I Voith Paper I twogether

EDITORIAL

Dear customers, dear readers,“Raw materials are limited – but ideas are not.” Voith Paper has taken this idea as its guiding
principle. In this edition of twogether you can read once more about our approaches to following
this principle. But first, the most important matter: the best ideas are worthless if they can’t be
implemented in practice.
For that reason, let’s be specific: Starting on page 6, the lead article in this edition outlines
Voith Paper’s concept of the Integrated EcoMill (IEM). The IEM is both ecologically andeconomically attractive and thus supports our customers in remaining competitive into the
future. Adapted to the respective location, the customized IEM concept can be used worldwide.
The Urban Mill variant, which is presented to you in the interview starting on page 13, is
specifically suited to industrial urban areas. Up to 20% of operating costs can be saved with
an Urban Mill.
The compatibility of ecology and economy is what we are concerned with – as expressed in
the guiding principle cited above. Examples are the customer-made waste water treatment
facility in the Swiss village of Perlen (p. 31) and the MultiForm IC forming fabric, which saves raw
materials and energy (p. 42).
New components or new machines from Voith Paper impress not just with their superior levelof productivity but also with their cost efficiency – especially in dealing with raw materials.
The world’s largest paper machine Hainan PM 2, a symbol of the most modern paper
manufacturing and almost 600 meters long, is synonymous with this (p. 16), as is the PM 1 inNantong (p. 20). The latter is also an emblem of genuine globalization, because this is thefirst time the largest Japanese paper group, Oji Paper, has invested in a paper mill located in
China.
That paper is not just a cultural asset but in equal measure a medium of the future was madeclear in a panel discussion of professionals that was initiated by Voith Paper (p. 68).
Representatives from a publishing company, a well-known library, Wikimedia and Greenpeaceagreed: “Paper is a medium with a future.” I’m happy to share that view.
Enjoy your reading!

On behalf of the Voith Paper Team

31 I 2010 I Voith Paper I twogether

3

CONTENT

Cover topic
Paper Technology Journal                 

IEM relies on complete process integration
Economical, environmentally friendly,
regionally adapted

6“Especially good for urban areas”
Interview with Markus Oechsle on the Urban Mill13

New plants
16

Successful startup of Nantong PM 1
Largest Japanese paper group invests in China

20

The right choice with new systems & rebuilds
Current projects at Voith Paper

24

Hainan PM 2 – the world’s largest
paper machine
Exceptional project jointly completed

On the cover picture
The global resources of fibers, energy andwater are limited and thus becoming evermore expensive. Voith’s Integrated EcoMill
confronts this scarcity and is attractive due
to a concept that protects the environment
and lowers costs.

4

Rebuilds
First Curtain Coater in board production
Curtain up for the DF Coat

28

Perlen benefits from tailor-madewaste water treatment
Clarification facility rebuild within the PLP

31

Rapid modernization on the headbox
Initial results of the new OnQ ModuleJet actuator

34

Operation “Screening Section Optimization”
The ScreenFit Doctors from Voith Paper in action

36

Hainan PM 2 – the largest paper machine in the world.

16

31 I 2010 I Voith Paper I twogether

CONTENT

Products on site

Spotlight: tissue“Our experience has been impressive”
Mitsubishi relies on non-contacting
caliper measurement

39

Tissue producers increasingly opting for
Voith Paper
13 machines in two years speaks for itself

56

Maximum dewatering performancefrom start to finish
E-Flex – the new generation of press fabrics

40

SolarSoft increases speed and saves energy
Higher tissue production profitability withpolyurethane roll covers

58

New forming fabric designfor board & packaging
MultiForm IC – expansion of the I-series

42

Service44
OnQ FormingSens increases efficiency
at Koehler Kehl, Germany
Detecting problems in the wire section in good time
Voith dBlocker effectively reduces noise
How quiet paper machines can be

45

Product combination achieves improved
coat weight profiles
Luna roll covers and mechanical roll service

48

Clothing, rolls and service from a single supplierInterview with Modern Karton, Turkey

50

New Technologies
Foam tanks are no longer required due
to deaeration pump
New development in deinking flotation
lowers investment costs

52

Higher efficiency through predictionof dewatering performance
The new “steps beyond cfm” concept

54First Curtain Coater in board production.

28

31 I 2010 I Voith Paper I twogether

Smurfit-Stone counts on Total Roll Management
Mutual trust and cooperation

61

Innovative roll maintenance saves money
Forward-looking service extends running times

63

CMMS – Computerized MaintenanceManagement Systems
Professional maintenance management bysystem supplier

66

Forum
“Paper is a medium with a future”
High-caliber speakers at panel discussion

68

Eco-friendly drive alternative forpublic transit buses
Voith Turbo’s hybrid gear saves fuel70

Turning old into new after 31 years
Overhaul for machine tools with
Voith Industrial Services

70

Merkel emphasizes the role of hydro powerin Germany
German Chancellor visits Voith Hydro

71

Tissue producers increasingly opting for Voith Paper.

56

5COVER TOPIC

6

COVER TOPIC

Economical, environmentally friendly, regionally adapted:

The IEM relies on complete
process integration
The Integrated EcoMill (IEM) from Voith Paper scores twice: fewer
resources are consumed and at the same time investment and operating
costs are lowered. This is facilitated by highly integrated sub-processes– both inside and outside the paper mill. The consumption of raw
materials, energy and water is thus optimized, which yields tangible
economic advantages. The IEM is both ecologically and economicallyattractive and is a sustainable alternative to conventional paper mills.

7

COVER TOPIC

With its concept of the completely

specific location factors are taken

in rebuilds. Markus Oechsle

integrated paper mill, Voith Paper

into account and integrated intoemphasizes: “With the IEM, we

is confronting the lack and increase

the overall concept. The resulting

succeeded in uniting various

in prices of resources and thecustomer-made solutions not only

specialized disciplines and gatheringrising cost pressure in paper

improve resource consumption, butthem together in an integrated

production. “We can clearly reduce

they also significantly minimize thesolution-oriented approach. This

consumption of resources in paper

investment costs and ongoing

especially demonstrates the

production and support ouroperating costs of an IEM.

expertise of Voith Paper.”while at the same time lowering

The integration of all relevant sub-Coordinated with the customer

their manufacturing costs,” explains

processes, whether they are inside

and the location

Markus Oechsle, responsible foror outside the production line,

Order Processing at Voith Paper.

makes the IEM economically andToday, high efficiency is essential

Oechsle continues: “A big

ecologically attractive. Markus

for success if a paper mill is toadvantage of the IEM is how it

Oechsle continues: “We coordinate

prevail in competition. For thatcan comprehensively take into

the sub-processes perfectly with one

reason, within the framework of aaccount the various location factors

another so that our customers profit

feasibility study, Voith Paper develops

and framework conditions to whichfrom considerable cost savings. This

the ideal solution for the customer’s

we need to individually coordinate theis achieved by designing theexisting conditions.

mill concept.”

components used in an optimal way,

customers in operating sustainably,

which results in a lower resourceFirst, it is a matter of selecting theIntegrated processes are

consumption.” The paper producer

suitable reference model from themore cost-efficient

therefore profits from the more

ready-made IEM reference portfolio,

efficient use of energy, water and fiber.

which is then individually adapted

Already in the planning of an IEM, theThe IEM concept can be smartly

to the location and the customer’sfiber, energy and water cycles andimplemented both in new plants andneeds. Various questions have to“We can clearly reduce consumption of resources in paper production
and support our customers in operating sustainably,
while at the same time lowering their manufacturing costs.”

Markus Oechsle

With integrated water, fiber and energy cycles, the IEM consumes less resources than conventional mills.

8

31 I 2010 I Voith Paper I twogether

COVER TOPIC

be answered in the process: Is the

The last step consists of drawing up a

new paper mill to be built in thecomprehensive economic efficiency

greenfield or in an industrial urban

calculation of the investment andarea? Which raw material would

operating costs for the customized

make sense? Can, for example, theIEM. Therefore, the financial risk forsurrounding industry be integrated?

the customer is minimized. Such

What production quantities shoulda business consideration shows

the paper mill achieve? These andthat economic advantages can comemany other questions are answeredwith sustainable ecological paper

in a structured way, and the results

production. The integrated solutions

are incorporated in the customized

provide for quick amortization of the

IEM concept.

investment in the IEM.

All parameters are individually

Using fibers efficiently andevaluated and contribute to thesensibly

overall assessment for the mill.
Thus, the requirements for electricity,

Depending on the location, use of

steam, water and chemicals are firstvirgin or recycled fibers is prefered as a

calculated. In the next step, theraw material. The idea of the IEM isinterrelation of all relevant sub-based on the fact that the existingprocesses is determined. This includes

location advantages are utilized in suchmodeling the mill for various stock

a way that they are included in thewas made to use eucalyptus pulp. The

compositions and production

overall concept in an economically andtransport costs for the raw material arequantities and representing theecologically sensible way. At the Trêsminimal. Due to the nearby pulp millvarious operating states for individual

Lagoas paper mill in Brazil, for

supplying the paper machine with

sub-processes (startup, shutdown,

example, the proximity of thesteam and power, it was not necessary

grade change, etc.). Finally, all systemproduction location to a pulp mill andto invest in a power plant. In addition,

components are put together in an

to the existing eucalyptus plantations

the waste water of the paper mill isefficient optimum.

was thus utilized. A conscious decision

disposed of in the pulp mill so that a

Location factors such as proximity to a
eucalyptus plantation are taken into
account in the planning of an IEM.

separate clarification facility was notnecessary.
In order to be able to serve the rising
global need for paper, however, theportion of recycled fibers in paper
production must be noticeably
increased. This is the only way that thevaluable wood resources can besustainably managed for responsible
production. The use of recovered paper
makes sense, especially in proximity toindustrial urban areas, since that iswhere the paper consumers and therecovered paper suppliers are. Shortapproach routes minimize the required
transport costs and the delivery time

31 I 2010 I Voith Paper I twogether

9COVER TOPIC

Today, a variety of paper grades can be produced from recycled fibers. The use of recovered paper in paper production is smart,especially near industrial urban areas.

considerably. In addition, using

all the while maintaining the quality

independent of external disposal

recycled fibers reduces the energy

level demanded.

companies.

Energy from residual materials

Through an economic evaluation,and sludge

the energy requirements of theconsumed during paper production.
Due to the enormous technological

IEM are adapted to the respective

developments of the last few
decades, the possibilities for

An IEM that is operated with alocal conditions. In doing so, ausing recovered paper fibers havehigh portion of recycled fibers has acomprehensive waste and energy

steadily increased. While somehigher amount of residual material.

concept is drawn up. Therefore, forgrades, such as newsprint papers,

A system for processing theseexample, integration of a biomass

are already produced by using up tomaterials is an economically sensible

power plant into a paper mill

100% recycled fibers, there is apossibility here, to lower the disposal

increases the latter’s efficiency.

change even at high-quality graphic

costs that tend to increase. The

papers.

residual materials are thermally

The minimized energy requirement

utilized in the process, whichof an IEM is an enormous competitive

Since 2004, the example of LEIPA

additionally lowers the energy

advantage if you consider that energy

Georg Leinfelder in Schwedt,

costs.

costs account for about 18-20% of
the total costs of paper production.

Germany, has shown that a ratio of
up to 100% recovered paper isWith the IEM, accumulating paper

The optimal use of energy is anpossible in the production of first-

sludge and rejects are used toimportant adjusting lever for ensuringclass LWC paper. On the PM 4 fromgenerate steam and electrical energy.

efficient paper production in theVoith, 360,000 tons of LWC paper

This is achieved with the application

future as well.

per year are produced with recycledof a fluidized bed boiler for solid

fibers as the raw material. In

fuels. Only a reduced amount of ash

As little fresh water as

Schwedt, Voith Paper succeeded forremains. These systems thus pay off

possiblethe first time in producing coatedwithin a few years because disposal

magazine paper grades with such aand transport costs are saved. In

The water cycles are integrated

high proportion of recovered paper –addition, the paper mill becomesthroughout the paper production

10

31 I 2010 I Voith Paper I twogether

COVER TOPIC

process, minimizing fresh water

Example: “Integro” paper millconsumption. The individual
consumers are optimized, waste

In order to be able to specifically

17 MW can be fed into the power

water is treated and the purified

identify some of the economical

network as biomass power.

water is used in as many places as

and ecological advantages of an

possible. The treated waste water

Integrated EcoMill, a practicalFresh water consumption should

can be used for cooling drives or as

example is used.

be reduced to a minimum throughsystems for water treatment andshower water, for example.
Machine data:

the integration of water cycles.

Not only does less fresh water

Paper grade: writing/printing paper

Residual materials can be burned

consumption mean lower costs, but

Raw material: recycled fiberin the power plant for energy

also in many countries there is water

Annual production: 220,000 tons

production, which at the same time
lowers the disposal costs.

scarcity, so that fresh water isa rarity. Thus reduction of fresh water

Initial conditions
Feasibility study ensuresconsumption is a real issue for paper

economic advantages

producers in these regions. ThroughA paper mill, hereinafter called

intelligent use of various water“Integro”, is designed to bequalities, Voith Paper is succeeding

constructed as an IEM in the

In the first step, various system

in noticeably reducing the need forgreenfield. A biomass power

concepts are investigated andfresh water.

plant that is integrated in theevaluated. The results at Integro

paper production process isshow that the total investment

IEM confronts global resource

planned for power and steam

costs including a biomass powerscarcity

generation. The total capacity ofplant amount to around 200 million

the power plant is estimated at

euros.

The resources required for paper

32 MW of biomass power. About

production are becoming ever more

15 MW of this is for the mill’s own

limited and thus more expensive

purposes, while the remaining

worldwide. In particular, theavailability of wood as the sourcefor virgin fibers is limited in themedium term. Fresh water and“Integro” concept: Integrated EcoMill with biomass power plant and water treatment.

fossil fuels are also coming up
against availability limits in many

Exhaust air

regions of the world.
Bio-gasOn the other hand, looking at various

Biomass

independent studies, Voith Paper
assumes that the need for paper –which today is about 400 million tonsPowerefficient resource-saving paper
production will be able to meet thisfuture need.

Heat recovery
Biomass
power plant
Steam

Recoveredpaper

Condensate

Biomasspower

Humid exhaust air
Paper

Auxiliaries
Water
treatment

Water
Fresh water
treatment

Waste
water
Water cycle

Metals31 I 2010 I Voith Paper I twogether

Energy cycle

Process line

Water

– will rise by 200 to 300 million tons
worldwide in the next 30 years. Only

SludgeReject
Water

Condensate

Waste water
treatment

Bio-gasWaster water

Ash

11

COVER TOPIC

Exemplary use of energy

water can be lowered to aminimum. At various points,

Thanks to the integration of a biomass

fresh water can be replaced bypower plant in the production line, aclear filtrate, super-clear filtrateconsiderable portion of primaryor bio-water, i.e., treated wasteenergy is saved. The steam generated

water. Therefore, a gradualin the power plant is fed to the paper

economization is achieved,machine – after the power generation

depending on the extent of

turbine. The PM thus becomes theintegration of individual sub-condenser for the power plant.

processes that are consistently

The integration of power plant andimplemented. At Integro,

paper machine enables the ideal

consumption of fresh water can

combined heat and power generation.

thus be reduced from 6 m3/t of

The energy is used in the power plant

paper to below 2 m3/t of paper.

for power generation and the heatof the hot steam is used in the dryer
section for drying the paper web.
At the Integro example, this led tosavings amounting to 20% of primaryenergy.
Need for fresh water isreducedWith the intelligent use of different
water qualities along the paper
production process and closed
cycles, consumption of fresh

By using different water qualities, fresh water consumption can be gradually reduced to
below 2 m3/t of paper.

8

Fresh water (m3/t)

7

Reference
6
5

Fresh water quantity fora zero waste water mill: 1.23 m³/t

1

4

Fresh water in water vapor,sludge and rejects: 1.15 m³/t

2

3

3

2

4

Fresh water in the paper: 0.07 m³/t

5

1
0
6
1
2
3

12

5

4

3

2

1

0

Waste water (m3/t)
4 Re-dilution by means of
Bio-water as supplement
super-clear ﬁltrate
Clear ﬁltrate for shower water (75%)
5 Bio-water for starch treatment
Bio-water as sealing water

31 I 2010 I Voith Paper I twogether

COVER TOPIC

In conversation: Markus Oechsle on the Urban Mill

twogether: What is meant by theterm urban mill?

“Especially good for urban areas”

Markus Oechsle: In general, urban

A special variant of the IEM is Voith Paper’s Urban Mill – anmills are paper mills that are built

integrated paper mill in the vicinity of an industrial urban

near their consumers. The respective

area. Along with low consumption of resources, papermakers

region is thus supplied with board

additionally benefit from low investment, operating and logistics

and packaging paper, printing andcosts. Markus Oechsle explains what is behind the Urban Millwriting paper, specialty grades orconcept.

tissue.
For some years now, we’ve seen atrend emerging in the paper industry:
more and more paper producers arebuilding their mills near industrial
centers. Due to the increasing use ofrecovered paper, proximity to the raw
material and the consumer andshorter transportation distances areof increasing importance to them.
twogether: And what is special
about Voith Paper’s Urban Mill
concept?
Markus Oechsle: What is newis the fact that these mills are
essentially integrated twice:First of all, integration into theindustrial surroundings, andsecond, integration of all relevant
sub-processes within the paper
mill. We are pursuing a ‘closed-loop’
approach, that is, the fiber, energy
and water cycles are nearly closed.
This immediately has several
benefits: investment, operating andlogistics costs are significantly
reduced. In addition, less energy
and water are consumed. And
hardly any residual material is leftthat has to be disposed of.
twogether: What does that look likepractically?

31 I 2010 I Voith Paper I twogether

13

COVER TOPIC

Markus Oechsle: Take the fiber

purified waste water is fed back into

production capacity to the conditions

cycle as an example. In the Urban

the papermaking process. In this way,on site and the optimal design of theMill, recovered paper collected in

fresh water consumption and theprocesses and system components

the urban center is prepared andaccumulating waste water can beboth lead to lower investment costs.

processed into new paper. If

reduced to a minimum.

Delivery from one hand decisively

additional virgin fibers are required,contributes to this. The specificthey can be purchased from theWhat is also important here is thatcosts for both small and large

market. The use of fibers fromthe Urban Mill is not viewed in

production facilities are quite

recycled paper also lowers theisolation; the industrial surroundings

similar.

consumption of primary energy

are also considered. Waste material

because virgin fibers are much more

and waste water from outside the

In comparison with conventionalenergy intensive to prepare.

paper mill can thus be reused in thepaper mills, a higher cash flow is

Urban Mill.

generated and a quicker return on

In the energy cycle, the heat

investment is achieved. Investment

generated within the papermaking

In short, all processes in the Urban

in an Urban Mill is highly attractive,

process can be reused. In addition,

Mill are optimally adjusted with one

not just from an ecological perspective

the transformation of waste materials

another and to the existing regional

but also from an economic point of

into steam and electrical energy

conditions.

view.

potential recyclables are sorted

twogether: Lower resource

Since in the case of an Urban Millout in a smart way and reused.

consumption means lower operating

the paper is consumed in theThat lowers the disposal costs.

costs. Is there any additional saving

surrounding urban center, thispotential?

lowers the ever-increasing transport

noticeably reduces costs. Also,

We also aim for closed water cycles

costs. Of course, the same applies

to minimize water consumption.

Markus Oechsle: Yes, by all

for the procurement of recovered

Cooling cycles are closed andmeans, adaptation of the of thepaper.

“Investment in an Urban Mill is highly attractive, not just from an ecologicalperspective but also from an economic point of view.”

Markus Oechsle

Energy cycle

Paper

Virgin ﬁbers
Fiber cycle

Urban area
Recovered paper
Water cycle

Paper mill

14

31 I 2010 I Voith Paper I twogether

COVER TOPIC

Recovered paper is becoming more
and more important in papermaking.
Already today it makes up more than
50% of the raw material for paper
production. We assume that in a few
years worldwide paper production will
use more than 70% recovered paper.
Since a lot of recovered paper
accumulates in an urban area, it canbe gathered at the front door of the
Urban Mill, so to speak. Proximity to
the end consumer of the paper, who
is at the same time the raw material

Low transport costs:
the Urban Mill is close
to the population,
which is at the sametime paper consumer
and supplier ofrecovered paper.

supplier, pays off here.
twogether: How do you proceed witha new Urban Mill project?

with one another. In addition, theMarkus Oechsle: As alreadycost effectiveness and efficiency ofmentioned, it is especially suitable

Markus Oechsle: Initially, we havethe paper mill can be increased byfor industrial centers with highprepared neutral reference concepts

integrating alternative industries in

population density and existingfor the most important paper grades.

the surroundings of the paper mill.

infrastructure. This especially applies

Together with the customer, theFor example, municipal waterto growth markets such as India

respective concept is then adaptedclarification facilities, power plants

and China, for example. The required

to the local conditions within theand garbage sorting facilities are

infrastructure is frequently lacking inframework of a feasibility study. In

interesting in this connection.

the rural areas, but it is alreadypresent in the catchment areas ofother words, a detailed situation
analysis precedes every project. We

twogether: Are there countries orurban centers – the ideal surroundings

make sure that all sub-processes ofregions that are especially suitable

for an Urban Mill.

papermaking are optimally coordinatedfor the Urban Mill concept?

31 I 2010 I Voith Paper I twogether

15

NEW PLANTS

Exceptional project jointly completed

Hainan PM 2 – the largest paper machine in the world
In May 2010, Hainan PM 2, with a wire width of 11.8 m and a length of almost 600 m, started up
successfully. The huge paper machine hall called for maximum fitness on the part of the erectors andstartup personnel. Furthermore, the Hainan climate, with high humidity and temperatures sometimes
exceeding 40°C, presented a great challenge for man and machine.

It all began with a letter of intent for

papermaking process. The latter is10.5 liters stipulated by the Chinese

three large paper machines, signed

achieved through an increase in thegovernment. Comparable fine paper

by Teguh Ganda Wijaya, CEO ofcoat application by means ofmachines in Europe require, on

Asia Pulp and Paper (APP). Among

pigments (mainly ground limestone).

average, about 8 liters per kilogram

Guangxi BM 1 and Hainan PM 1,

APP’s member of the board, Jensenof paper produced. Due to the

APP planned Hainan PM 2 – theKo, commented to the media just a

reduced use of fresh water, thelargest paper machine in the world.

few months ago that of foremost

quantity of effluent is also reduced.

On July 6, 2007, the work for theimportance to his Group is combining

The mill's own water preparation

paper machine, which should exceed

state-of-the-art papermaking withsystem at APP in Hainan has a

all present dimensions, was started

resource conservation. The new PM 2

capacity of 100,000 m³ per day.

with the engineering order.

from Voith Paper will live up to thisclaim. The fresh water consumption in

Enormous logistic challenge

APP places great importance on thethe overall plant per kilogram of paper

reduction of fresh water and the

produced is around 5 liters, wellAn exceptional project like Hainan

minimal use of virgin fibers in its

below the maximum consumption of

PM 2 requires good preparation, from16

31 I 2010 I Voith Paper I twogether

NEW PLANTS

Technical specifications
Stock preparation
DIP

355 t/day

NBKP

710 t/day

LBKP

1,655 t/day

BCTMP

1,185 t/day

PCC

700 t/day

Paper machine

JHPP
Hainan Jinhai Pulp & Paper Co., Ltd. (JHPP) – a subsidiary of APP – is thelargest pulp manufacturer in China and among the largest in the world.
Since November 1994, JHPP has been producing on an area of 4 km² andemploys 1,600 workers. Production covers not only pulp and tissue, butalso art paper and brochure paper of the highest level, as well as highquality packaging, folding boxes and calendars up to a basis weight of
250 g/m².

Uncoated paper weight:

151.1 g/m²

Finished paper weight:

255.3 g/m²

Wire width:

11,800 mm

Maximum operating speed:

1,700 m/min

Design speed:

2,000 m/min

Speed of Janus:

1,500 m/min

Speed of VariPlus:

2,500 m/min

Parent roll diameter:

3,500 mm

Maximum production:

4,537 t/day

the beginning. In a two-day seminar,

were specially made. For thewere able to be finalized quickly.

all of the participants met and learned

production and erection of the

As APP and Voith Paper havetheir roles and the purchase order.

10 Voith LSC measuring frames –already cooperated successfully

In addition, rules for joint cooperationeach one more than 14 m long –and with confidence on otherwere developed. Afterwards thean additional extra-large hall was

projects, only a few visits to thework started at Voith Paper: Layouts

rented. Another difficulty wasworkshop for approvals were

were developed, and components

sourcing steel, as it had become

necessary for the implementation.

with long delivery times had alreadyscarce in the world marketplace, andbeen ordered. At this machine

capacities had to be reserved early.

Due to the enormous size of themachine, logistics also presented awidth, modifications had to be carriedout even in the Voith workshops inThanks to diverse preparatory work

major challenge. Since it is notorder to handle the wire width offor the other two machines, Guangxi

always easy to transport long

11.8 m and the corresponding

BM 1 and Hainan PM 1, both parties

machine parts to the seaport, allweights. For the 87 dryers in thewere clear about the demands madepossible transport routes were

paper machine, new pouring holeson the new machine, and the layouts

investigated in detail. The press

31 I 2010 I Voith Paper I twogether

17

NEW PLANTS

DynaCoat on-line coating aggregates.

One contact for all automation related questions.

Wet end with DuoFormer TQv
and Tandem NipcoFlex press.

section alone, with a weight ofof all participants in the processing

expectations, and we assume theapproximately 500 t, requiredin order to pack the parts in adesign values of the machine will beseveral low bed trailers and special

strategically favorable way.

reached very soon.”night transport, as well as police
escort, to reach the ship. In 18

After the interruption the installation

partial shipments, approximately

work began. In just 11 months of

1,500 containers plus 888 large

installation supervision, sometimes

transport units with a total weight ofunder the most arduous conditions,

30,000 t were taken to China. JHPP

the goal of “paper at reel” washas its own port facilities in which

achieved on May 18, 2010. Since

the shipments of large machinerythat time, the machine has achieved

could be received, whereas thea maximum speed of 1,415 m/min,containers were unloaded in thewith an average of 1,350 m/min.

next village, Yangpu, a few minutes

The threading record to-date fromaway. The construction work andthe press to the Sirius reel is only

installation of the machine were

18 minutes – at a machine length oforganized by the customer itself.

almost 600 m.

“Paper on reel” 11 months

Huang Yifeng, project manager andbe reached by air. The paper mill is locatedafter project interruption

Vice President of JHPP, is very

about two hours from the airport in an

satisfied and confident: “We areindustrial development zone on the northBecause of the recession in China

pleased to be able to work together

coast of the island.

after the Olympic Games and thewith Voith Paper again on thisglobal financial crisis, the projectproject, the world's largest paper

had to be interrupted for one year.

machine. Voith Paper's machine

Therefore, it was necessary toconcept ensures the planned

properly register, preserve and store

production capacity of Hainan

the shipments. A great deal of

PM 2. Right from the beginning,

discipline was called for on the partthe machine capacity met our

Location
China
PekingShanghai

HainanHainan Island is located in the South China
Sea separated from the Chinese mainlandby the Qiongzhou Strait. The capital in thenorth of Hainan is Haikou, which can also

18

Contact
Johannes Rimpf
johannes.rimpf@voith.com

31 I 2010 I Voith Paper I twogether

NEW PLANTS

Parentroll transport to the Janus calender.

Perfect drying capacity due to contactless
infrared drying.

Scope of supply Hainan PM 2
Tandem NipcoFlex press
DuoFormer
TQv

Top DuoRun pre dryer section

SpeedSizer

SpeedSizer

Sirius rereeler

Speed Sizer

Sirius

4 DynaCoat

Janus

Top DuoRun
after dryer section

VariPlus

2 x parallel

Stock preparation system with a total capacity of 3,750 t/day to prepare long fibers, short fibers and BCTMP. Energy efficient and gentle refining for optimal
fiber development by utilization of the latest PLURALIS refiner fillings in the TwinFlo refiners.
All roll covers for the production line as well as 50% of the startup clothing and all doctor blades were supplied by Voith Paper. Additionally there is a “Total
Roll Management” (TRM) contract for Hainan PM 2 (more about TRM on page 61).
Continuous automation package with some 20,000 I/Os for MCS and DCS, 10 measuring frames with 54 sensors and a monitoring system with 1,400 single
measuring points a. s. o.
Complete system solution for contactless drying consisting of three gas-heated IntegratedDryer infrared dryers, four gas-heated InfraAir heating units,
12 MCB-Dryer air dryers and two CB-Turn airturns.

31 I 2010 I Voith Paper I twogether

19

NEW PLANTS

The largest Japanese paper group invests in China

Successful startup of Nantong PM 1
In the summer of 2008 Jiangsu Oji Paper placed an order with Voith Paper to supply a complete
production line for high-grade woodfree coated and uncoated papers. In its 130-year history, this isthe biggest investment the Oji Paper Group has made in China so far. Just two years later, in May of2010, the so-called “China Stars” was successfully started.

The Nantong PM 1 was awarded to“To reduce the number of suppliersdelivery were coordinated more

Voith Paper in a total package as aand thus the interfaces, we decided tosimply and quickly.

Process Line Package (PLP). This isaward the contract for the supply ofespecially remarkable since Japanese

the complete Process Line Package

Less energy and fresh water,

paper manufacturers frequently(PLP) to Voith. This enabled us tofewer costs

purchase the individual components

handle the entire greenfieldof their paper machines from different

installation with very few people.”

suppliers. However, the PLP concept

In addition, the Process Line Package
offers Oji Paper the advantage thatoffers Oji the advantage of saving

Installation and startup were also

the strength of Voith Paper as process

resources in its own project team:simplified by the total package

provider fully takes effect. Thus inVoith Paper takes over coordination

approach. Ultimately, only Oji Paper,

the case of “China Stars” a conceptof all sub-suppliers. “Nantong PM 1

its erection contractor and Voith

was developed that is designed foris Oji Paper's first new paper mill inPaper were involved. By means of

reduced energy consumption and

China,” explains Muraji Nishi, project

these few interfaces, changes in theless use of fresh water. Pumps

manager of the production line.

schedule or what is included in thewith frequency converters are an

20

31 I 2010 I Voith Paper I twogether

NEW PLANTS

example of this. Surely they

represented on the Chinese market

due to the good infrastructure of theinvolve a somewhat higher initial

by only one sales office in Shanghai.

economic and development zone

investment, but already after a

But the corporate group had alreadythere and the proximity to Shanghai.

short time of operation, they pay

been intensively occupied for several“Due to its proximity to the Yangtze

for themselves through lower

years with construction of a paper

River, we can get the water fromenergy consumption.

mill in China so as to expand its

there. In addition, we have accesspresence in this market and to utilize

to the sewer built by the municipal

The machine concept was

the market potential even more.

authorities to the Huang Hai Sea.

developed in close collaboration

Fewer transport and personnel

From an ecological viewpoint, thisand tailored to the requirements

costs made on-site production

is another advantage of this location,”of Oji Paper. From stock preparation

economically interesting for Oji

says Hiroyasu Hayano, manager atto the winders, the technicalPaper.

Jiangsu Oji Paper.

Ecological location advantages

Long-term service support

at the Voith Paper Technology

The city of Nantong in the province

A special feature of the project isCenter (PTC) in Heidenheim,of Jiangsu was selected as thethe proximity to the Voith Paper

Germany.

location for Oji Paper’s first paper

location in the Chinese city ofmill in China. Nantong is at the mouth

Kunshan. This also simplifies

Until the decision in favor of theof the Yangtze River and offers

collaboration after startup of the

Nantong PM 1, Oji Paper was

optimal preconditions as a location

facility. Only a one-hour drive from

specifications were worked out inmany joint discussions andsubsequently confirmed by tests

DuoFormer TQv

Tandem NipcoFlex press+ 3rd press

SpeedSizer

Top DuoRun pre dryer section

Combi DuoRun
after dryer section>>> Info: Nantong PM 1
The Nantong PM 1 produces fine paper and coated wood-free paper in thebasis weight range of 40 to 190 g/m². With a wire width of 8,200 mm, it isdesigned for production speeds of up to 1,600 m/min. Along with stock
preparation for processing the pulp delivered as bales, the facility consistsof a paper machine with SpeedSizer and EcoCal calender, a rewinder,
off-line coating machine, two Janus calenders and two winders.

31 I 2010 I Voith Paper I twogether

EcoCalcalenderSirius reel

Rereeler

In addition, the delivery includes the entire process equipment such as
piping, containers, tanks, pumps, mountings, instruments, steam andcondensate system, machine ventilation technology with drying hoods andan extensive automation package with process control system (DCS),
quality control system (QCS) and electrification.

21

NEW PLANTS>>> Info: Oji Paper
The Oji Paper Group with headquarters in Tokyo,
Japan, was founded in 1873 and consists of Oji
Paper Co., Ltd, as well as 193 subsidiaries and84 affiliates. These companies are active in a wide
range of business fields, including pulp and paper
products. Additional business fields include theproduction of chemicals for the papermaking
process or wood and tree-planting. Oji Paper
produces graphic, board and packaging,tissue and specialty paper grades.

22

31 I 2010 I Voith Paper I twogether

NEW PLANTS

Off-machine coater with 4 blade coaters

2 off-line Janus calenders

VariPlus winder

Nantong, the entire know-how of

spreader rolls is taken over by theVoith Paper and quick support if

Voith location in Kunshan. For this, aneeded are available here.

framework agreement was concluded,
which simplifies handling of these

Since the time during and afterorders and offers additional economic

startup is a big challenge for theadvantages for Oji Paper.

Location
China
Nantong
Pekingnewly assembled maintenance teams,
Oji Paper concluded a mill service

Shanghai
Prospects for the future

consulting contract for three years
with Voith Paper for the PM 1. The

Oji Paper is already planning theprofessional consulting in planningnext expansion stages: Thus in thethe maintenance and service work

future the pulp required for paper

and the supervision of repair work

production will no longer be imported,are decisive for quickly achieving

but rather produced on site in a new

production and efficiency goals.

pulp mill at the Nantong location.

Thanks to the service contract and

The preparations for construction of

the cooperative collaboration ofthis pulp mill, which will be designed

Voith and the Oji Paper Nantong

for the needs of two paper machines,

maintenance team, effective service

are fully underway. In order to ensure

is assured along with high plant

the supply of raw material, Oji Paper

availability.

has acquired tree plantations in

The city of Nantong is not far from
Shanghai, on the northern bank of the
Yangtze River. One of the special featuresof the economically up-and-coming city isthat many Japanese companies have theirChinese headquarters here. The infrastructure
in Nantong is ideal: the city is linked byexpressways in all directions and has alarge seaport.

ContactAndreas Köhler
andreas.koehler@voith.com

China. Also, the expansion of the
For support with maintenance andpaper mill with a second paper

troubleshooting, a seven-member

machine has already been approved

team from Voith Paper is on site,

by the Chinese authorities. Thesetaking care of the mechanical,

planning steps show how Oji Paper

hydraulic and pneumatic systems

wants to strengthen its presence

as well as lubrication and automation.

in the Chinese market to participate

In addition, the grinding of rolls andin China's increasing demand forservice for suction, press andpaper.

31 I 2010 I Voith Paper I twogether

23

NEW PLANTS

With new plants, a system provider is inProcess know-how leads
to records
With new plants, Voith Paper shows
its strength as a system provider within-depth knowledge of all processes
in the global paper industry. The
main focus is on paper machinesthat play a leading role in efficiency,
quality, speed, safety andenvironmental friendliness. The latest

For highest

examples highlight these strengths:

speedsKing’s Lynn PM 7 (Palm GmbH & Co.
King’s Lynn PM 7

KG), DongHae PM 1 (Moorim Paper
Group), PM 1 in Nantong (Oji Paper

The design speeds of the latest projects speak for themselves:
2,200 m/min newsprint (Palm GmbH & Co. KG, King’s Lynn PM 7)
2,000 m/min fine paper (Asia Pulp and Paper, Hainan PM 2)
1,500 m/min fine paper (Moorim Paper Group, DongHae PM 1)

For first-class

Co. Ltd), PM 7 in Perlen (Perlen
Papier AG) and Hainan PM 2 (Asia
Pulp and Paper).

quality

Hainan PM 2

It is not just sophisticated technologies that are required to produce high-quality paper. Beyond that, comprehensive knowledge of thepapermaking process and the factors that influence it are essential. Voith Paper’s decades-long experience ensures the desired paper
quality at a constant level.
Furthermore, the high quality of the processes and products make exceptional projects such as Hainan PM 2 possible. In constructing thelargest paper machine in the world, Asia Pulp and Paper (APP) needed a quality supplier and chose Voith Paper.

24

31 I 2010 I Voith Paper I twogether

NEW PLANTS

demandWith all orders, Voith Paper’s
comprehensive know-how and many
years of experience were decisive.
Thus, for example, the One Platform
Concept is acknowledged as amilestone for standardization. As
professional project execution ofthese complex systems becomes
ever more important, Voith systems
meet these demands head on. So
that all the components in a project
could engage with each other like
cogwheels, Voith Paper developed
the Process Line Package. ThisFor more

environmental
awareness

Perlen PM 7

meant the world’s largest production
facility for newsprint in King’s Lynn
could be built in only 16 months.

The world’s largest deinking facility is at Palm Paper in King’s Lynn, England. Every day,
1,500 oven-dry tons are turned out. Moorim Paper has ordered the first integrated paper mill forSouth Korea, with the DongHae PM 1 from Voith. Through the resource-saving overall concept
used at Perlen Papier in Switzerland, power and steam use were minimized leading to noticeably
lower energy consumption. Even the consumption of virgin fibers was reduced.

For increased

efficiency

Nantong PM 1
Voith Paper’s One Platform Concept concentrates not only on the overall process but above all on the life cycle of the products. It also includes
maintenance work, rebuilds and services for continuous process improvements. The One Platform Concept permits the supply of complete packages thatare precisely matched to the requests and requirements of the individual customer. With the Process Line Package, Voith simplifies the engineering,assembly, startup and training processes. Thus Oji Paper awarded the Nantong PM 1 to Voith Paper as a total package. The advantage: fewer interfaces,
quick coordination and full use of Voith’s process know-how. The result: an efficient project execution and an efficient paper machine.

31 I 2010 I Voith Paper I twogether

25

REBUILDS

Rebuilds increase added value and improve
Efficiency

increased

Components from Voith Paper
suitable for every type ofmachineQuality, productivity and production
costs are the measure of all thingsin the paper industry. Rebuilds
and modernizations ensure that
production lines are up to dateand improve their performance.
The added value can thus beincreased and the highest levelsof efficiency, quality, speed, safety

Higher runability and shorter roll change time
A new deflector on the headbox at Adolf Jass, Germany, improves the paper quality andincreases the runability of the machine. The rebuild of the winder has more than halved thechange time of the parent rolls at Burgo Ardennes, Belgium.

and environmental friendliness are
attained.

Speed

increased

Activeenvironmental protection
Less need for energy and fresh water
At SCA Witzenhausen, Germany, energy use has been significantly lowered by rebuilding
the pre dryer section.

26

Component replacement for higher
web speeds
The new threading system with internal Venturi
vacuum technology in the PM 1 at Rhein Papier,Germany, allows reliable threading at a speed of
up to 2,200 m/min.

31 I 2010 I Voith Paper I twogether

REBUILDS

the eco-balance
HigherParticularly when it comes torebuilds, Voith Paper views theavailability

production line and processes
as a whole – from optimizationof raw material to roll handling. It
does not matter whether the paper
machine is small or large, decades
old or still relatively new. The
goals are minimal investment
costs due to the most extensive
use of intact components, short
downtimes and quick amortizationof total costs.
Fewer breaks and reliable drives
The PM 6 at Nettingsdorfer, Germany is a prime example of how availability can be increased
through rebuilding. Voith drives in the entire dryer section give energy savings and reliable
operation. Since Weig Karton relocated the doctors on the wire drive roll by 90 degrees on the
KM 6 in Mayen, Germany, breaks have been noticeably reduced.

Preventive

service
The winder rebuild at Kübler & Niethammer,
Germany, had the effect of increasing the
speed. Furthermore, the winder was brought
up to the current safety standard.

31 I 2010 I Voith Paper I twogether

Reducing downtimes
The Slovakian Ruzomberok PM 18 of the Mondi Group is well-known as the world record machinefor Single NipcoFlex presses. To keep this record into the future, the machine undergoes regularpreventive maintenance; which brings the steam joints and spoiler bars, for example, up to thecurrent technical state of the art.

27

REBUILDS

Curtain up for the DF Coatany plugging of the nozzle so far.
Even threading through the coatingFirst Curtain Coater inboard production
Perfect coverage and outstanding print characteristics. No moreand no less than this is required for the coat application. That’s
why board producer Mayr-Melnhof relies on the Curtain Coater from
Voith Paper.

unit worked very well.
Advantages for the customer
and the environment
The DF Coat is operated in its total
speed range with a coating color of
approximately 60% solids content,
which is a clear increase, leading to a
substantial reduction in energy costs

At the Austrian location of Frohnleiten,

bubbles from the coating color –an air knife had previously been

because where there is air, there

used in the BM 3 for the middle coat.

cannot be any color.

The unit led to some limitations.
The maximum machine speed wasof over 40% for the middle coat line.
With the higher solids content in thecoating color, the amount of latex

Higher quality and speed

550 m/min and the maximum solids

used could be reduced by 2% in thefirst step. Further savings are possible

content was 42%. In addition,

After the first few months incoverage of the board by the air

operation, the results achieved areknife was only moderate, and thequite impressive. First of all, therunning characteristics were impaired

increase in quality is remarkable.

by breaks and frequent cleaning

Applying the middle coat with theintervals.

DF Coat visibly improves coverageand cloudiness. This can be seen

In order to eliminate all thesequite well, for example, with dyed

limitations, a Curtain Coater was

samples of triple-coated board.

installed with the aim of replacing
the air knife over the medium term.

In addition to the enormous increase

The main delivery consisted of thein visual characteristics, there is

DF Coat with precision nozzle,

also an unchanged end roughness

which is essential for uniform profiles

as compared to the air knife.

in CD and MD direction. Also, a

Furthermore, the flatness of thevery effective air boundary layer

board has improved, since lessremover was ordered along with amoisture gets into the board throughmodification of the web guiding

the coating color.

system, a climate hood and an
optimization of the infrared drying

As far as runability is concerned,

to facilitate further speed increases

the previous speed limitation due toand energy savings.

the air knife no longer applies. An
attempt is being made to increase

An important component was thethe machine speed of the BM 3

complete working station including a

to 1,000 m/min. The general

high-power vacuum deaerator. With

performance is very good – there

curtain coating, it is essential tohave been neither any breaks onremove even the very smallest air

the DF Coat nor have there been

28

Josef Gombocz and Johann Eggenreichfrom Mayr-Melnhof with Andreas
Hosemann and Stefan Reich from Voith
Paper (from right to left) inspect the
newly installed Curtain Coater. The
nozzle needs only a few seconds tomove into its working position.

REBUILDS

with changes in the pigment“When the DF Coat runs,

more elaborate is all around it. In

composition. In the area of raw

it runs.”

particular, it needs a constanttemperature, reduced air drafts

material, input savings are also
possible.

The fact that it should be >>> Mayr-and only a small amount of air in

Melnhof in Frohnleiten to order thethe color,” says Josef Gombocz,

After only a short time in operation,

first DF Coat is no coincidence.

Director of Coating Technology at

the high expectations for the first

The company’s innovative spirit has

MM Karton, about the coater’s

installation of a DF Coat in a board

been well known for a long time – thespecial features.

machine were met and even

first shoe press ever used in board

exceeded. Thanks to further

production is running in the

All these things are relatively easy to

optimizations achieved by thecompany’s BM 3.

provide. The DF Coat has its own
hood for creating the optimal climate.

customer together with Voith Paper, it
is possible to increase the quality of“Nobody wants to be the first,

Therefore, the ambient temperature

the product while increasing thebut everybody wants to be theremains constant, and disturbing air

machine output at the same time.

second, and that applies especiallydrafts are a thing of the past. The air

These advantages are supplemented

to curtain coating. The DF Coat inboundary layer remover eliminates

by cost savings and an improvement

itself, however, is a simple piece of

the air that comes with the paper web,of the global footprint.

equipment. What makes it somewhat

and the deaerator removes the air in>>> Info: Mayr-Melnhof Karton GmbHThe Austrian company Mayr-Melnhof KartonGmbH is the world’s leading producer of coatedrecycled board and the largest producer offolding box board in Europe. The Frohnleiten mill,founded in 1888, is the parent mill of the MM
Karton Group. The products are to some extent
converted within the company. With an annual
production volume of more than 40 billion
folding boxes, MM Packaging, the packaging

division of the MM Group, is one of thelargest folding box producers in the world.
Constantly striving for high efficiency and quality
improvements aroused MM’s interest in curtain
coating several years ago. After several tests
and intensive discussions with Voith Paper,
the first Curtain Coater for board was installed.
The DF Coat S started operation in Frohnleiten
mid-June 2010.

29

REBUILDS

the coating color. It has taken its
place in the former forklift room
alongside the BM 3.
“When the DF Coat runs, it runs:
simply and without any adjustments.
You don’t have to go into the hoodat all. We installed two cameras formonitoring so that in the control room
they always know what’s going on,”says Helmut Huss, Mill Manager in

Due to higher solids content of the coating color, energy in the drying section can besaved.

Frohnleiten. Maintenance of the
DF Coat is utterly simple. Spareseen in the smaller dimensions ofquality is excellent, and the energy

parts are rarely required, andthe pumps, among other things.

savings are remarkable. “The wholeduring operation the maintenanceeffort is extremely minimal.

team is delighted with the new unit,”
Of course, there are also doubts

says Huss. The Project Manager ofwhen you tread new paths – in this

MM Karton, Edmund Stadlhofer,

The perfect color developed

case, especially regarding the amountsummarizes the rebuild project briefly.

togetherof air in the coating color. In operation,“There is not much that is new in

it turned out that these concerns

coating technology – with one

It was a big challenge to develop awere unfounded. Josef Gombocz is

exception.” He points to the DF Coat:suitable coating color, since theimpressed: “Even though all pipes“This is the future.”

ultra-thin curtain must not tear if

were full of air after a shutdown, wethere is a draft of air. Together withstill didn’t have any air in the color.”

Voith Paper, Josef Gombocz developed
the perfect color composition for this.

The first results reinforced Mayr-

The amount of color in circulation is

Melnhof's pioneering decision:much lower than that in a conventional

using the unit is easy, threading at

coating unit. The difference can be

the DF Coat works fine, the end

The amount of color in circulation is verysmall.

Maintenance of the DF Coat is extremely
simple.

Location
Austria
ViennaFrohnleiten
Mayr-Melnhof
Frohnleiten is located in the Austrian federal
state of Styria, approximately 170 km southof Vienna. The small town is located on the
Mur river, in a picturesque valley surroundedby mountains. Frohnleiten looks back on
a 700-year history, and it has about
6,100 residents.

Contact
Stefan Reichstefan.reich@voith.com

30

31 I 2010 I Voith Paper I twogether

REBUILDS

Project goalst%PVCMFIZESBVMJDDBQBDJUZGSPNN©IUP N©I
t%PVCMF$0%MPBEGSPNUEUPUE
t3FCVJMEEVSJOHPOHPJOHPQFSBUJPOt3FVTFBTNVDIBTQPTTJCFGSPNFYJTUJOHTZTUFNt-PXFTUQPTTJCMFJOWFTUNFOUWPMVNF
t4JNQMJGJDBUJPOPGPQFSBUJPOSecondary clarifier at Perlen.

Double capacity: rebuild of the clarification facility within the Process Line Package

Perlen benefits from tailor-madewaste water treatment
At Perlen Papier AG, Voith Paper demonstrated how a waste water treatment plant can be rebuilt
during ongoing operation in order to double its capacity. With the rebuild, the hydraulic quantity wasincreased from 500 m³/h to 1,000 m³/h. Instead of a COD load of 25 t/d, today the facility is designed
for a capacity of 50 t/d COD.
At the beginning of 2009, Perlen

not designed for this, Voith Paper

replacement solutions were

Papier AG decided to expand its

worked out a plan for the expansion

necessary for the rebuild of existingproduction by adding a new Voithof the plant. It included an increase

units. Based on a thorough analysis

paper machine with stockin capacity with extensive use ofof all boundary conditions, several

preparation. From the beginning, it

existing system technology.

possible expansion scenarios were

was clear that with this investment

developed. Perlen Papier ultimately– despite use of the most modern

Expansion during ongoing

decided to continue relying on

paper machine technology – theoperation

purely aerobic waste water treatment.

hydraulic waste water quantity and

The final system comprises two

the COD load of the waste water

A particular challenge of this rebuild

identical waste water treatment

was expected to be double. Since

was that operation was supposed tolines. Both individually adjustablethe existing clarification facility wascontinue at all times and thuslines take half of the total load.

31 I 2010 I Voith Paper I twogether

31

REBUILDS

New reactors increase
treatment efficiency
For the rebuilding of the clarification
facility, the latest generation of>>> Moving Bed Biological Reactors>>> Info: Moving Bed Biological Reactors (MBBR)
The MBBR reactor is a key component of aerobic waste water treatment. These types of reactors
are mostly suitable for low to medium concentrated waste water with COD concentrations below
2,000 mg/l. Carriers provide a surface on which the activated sludge can grow. Typically, in MBBRs up
to 50% of the COD load is degraded within a small volume. The carriers covered with biomass can be
kept easily in the basin by means of a retention basket. Due to the very thorough mixing and the large
available surface on which the carriers, the level of mass exchange and biological activity is high.

(MBBRs) were used. The treatment
efficiency of the existing basins canbe increased by means of the new

In the second step, the side line wasconventional carriers they cannot

high-performance carrier. Therefore,

shut down and an activated sludge

clog. The carrier material continues

only one additional MBBR was

basin and secondary clarification

to keep its good fluidizationneeded to double the capacity. The

basin were taken out of operation.

characteristics and high degrees offollowing activated sludge system

Within a few days it turned out that

degradation. For this reason, thewas changed to a cascade with finethe new components were operating

conventional carriers in the existing

bubble aeration. This led tosuccessfully and the rebuild of the

MBBR were also replaced.

siginificant savings with regard tocomponents taken out of operationenergy and space requirements.

could begin.

The existing secondary clarification

In order to achieve the specified
discharge values, further activatedtanks were upgraded to improve

In further steps, the rebuilt basinssludge treatment is required after

their performance and an additional

were put back into operation andthe high load stage. In modern

MERI secondary clarification tankothers were freed for the rebuild.

facilities this is designed as

was built in order to handle theAfter the last rebuild, the full capacity

completely mixed cascaded basins.

new volume flow. Intermediate pipeof the waste water treatment system

For aeration in this area, porouslines were installed so the new

was available in good time prior tohose-shaped aerators are used,components could be seamlessly

the startup of the new paper

which have low energy consumption

put into operation. Like this, othermachine.

and contribute to the high operational

components could be taken out

reliability of the facility due to theirof operation for rebuild. An obsolete

Novel carrier material shows

rugged construction. A scraperside line with low capacity wasits impact

bridge with a suction scraper fromshut down.

MERI is installed in the new
The novel carrier material used insecondary clarification basin.

Rebuild in 4 phases leads to

the MBBR reactors at Perlen is

Additional monitoring units, sludge

success

attractive due to its higher

level measurement and floating

performance. In comparison withsludge detection allow automatic

The smooth course of the changes

conventional carriers, it has an active

operation. Wireless data transfer

during ongoing operation was criticalsurface that is up to six times larger

to the success of the rebuild. In the

per cubic meter of material used.

first step, an additional MBBR andAlong with a sufficient and uniformthe new secondary clarification basin

air supply, this is decisive for highwere installed.

effectiveness. The carrier material is

The discharge edifice to the receiving

porous so that the bacteria can bewater was also moved to anotherimmobilized in the pores. The carriers

location. Altogether with new pipe

resemble round plastic chips androutes, the preconditions were

their size is roughly that of a 1 euro

now set for initiating the next

coin. A special feature of therebuilding measures.

plastic chips is that compared to32

Thanks to the large active surface, the novel
carrier material shows a high performance.

31 I 2010 I Voith Paper I twogether

REBUILDS

Existing waste water treatment plant

Secondary clariﬁcation
basin 3Upgraded waste water treatment plant

Active sludge
basin 3

Secondaryclariﬁcation
basin 340

Preliminary
clariﬁcation 1
Settling basin 1

Cooling 1

Cooling 1

Settling basin 1

Activesludgebasin 3Cooling 2

Preliminary
clariﬁcation 1

Cooling 2

Moving Bed
Biological Reactor 1
Moving Bed
Biological Reactor 1

Moving Bed
Biological Reactor 2

Secondaryclariﬁcation
basin 4

SKS

Settling basin 2

Settling basin 2
Activesludgebasin 4

System configuration before rebuild.

Active sludge
basin 4

Secondaryclariﬁcation
basin 4

Secondaryclariﬁcation
basin 5

System configuration after rebuild.

feeds the operational data of the

The intention was to use the existingthat the full capacity of waste water

clarifier to the control system of thebiomass during the conversion in

purification was available at an early

paper mill. The amply dimensioned

order to keep the treatment efficiency

stage before the startup of the new

floating sludge removal device is

at a constantly optimum level. During

paper machine.

automatically activated. Anotherthe rebuild of the old reactor, thespecial feature of the secondary

new MBBR thus had to deal withclarification is the clear waterloads that were noticeably higher

removal equipment. It is submerged

than it was designed for.

Location
Switzerland

so that no growth of algae canPerlenPerlen Papieroccur at the outlet duct, which is

Short communication routes, very

often a problem with conventional

good coordination of the individual

serrated weirs. In addition, it allows

components and few interfaces were

uniform removal independently ofadvantages of the Process Lineweather conditions.

Package that persuaded Perlen

The small village of Perlen is surrounded

Papier to award the entire project toby mountains in the southwest canton of

Performance tests during theVoith Paper. Responsibility for the

Lucerne in central Switzerland. It is between

rebuild phase

paper machine, stock preparation

the Reuss and Ron valleys, not far fromand waste water treatment thus

Lake Lucerne.

Careful planning by Voith Paper al-came from one source. This led to aready paid off in the implementation.

smooth rebuilding process, so

BernContact
Axel Gommel
axel.gommel@voith.com

Dieter Efinger
dieter.efinger@voith.com

Retention basket for MBBR carriers.

31 I 2010 I Voith Paper I twogether

33

REBUILDS

Initial results of the new OnQ ModuleJet actuator

Rapid modernization on the headbox
Board producer Moritz J. Weig GmbH in Mayen needed a solution for its outdated profile controller
system on the headbox. Because of the harsh environment, the actuators no longer worked reliably,
so that along with downtimes, there were unwanted fluctuations in the basis weight profile. With
the customer, Voith Paper developed a cost-effective modernization solution in which the new
OnQ ModuleJet actuators were used for the first time.

t Depending on the valve

In order to make the existing system

OnQ ModuleJet actuator system

resistant to the rugged environment,

guarantees good and uniform basis

construction, the actuators canan overhaul of the 79 actuator motors

weight cross profiles. In order toeven be exchanged during

was necessary. However, Voith Paper

withstand the difficult operating

operation within 10 minutes,

had another suggestion that turned

conditions and guarantee highwithout parameterizationout to be technically ideal for theavailability, OnQ ModuleJet offers

requirements of Weig Karton: thesome important advantages:

class IP67 – it is protected against
environmental temperatures up to

newly developed OnQ ModuleJetactuator. Thanks to its compact

t Separated from the motor unit, thedesign, a high protection class (IP67)

electronics can be installed so theyand thus greater reliability, andare protected from the white water

serviceability, this proved to be themost economical solution.
Low investment ensures hight The actuator meets the protectiont One electrical unit controls up to

70°C and water jetst A faster and more secure Ethernet
field bus (100 Mbit) allows extensive
diagnosis up to the motor unit

eight actuators and takes on thecommunication with the OnQ

In a project time of just four weeks,

Profilmatic control computer

Voith Paper developed an automation

availability
The OnQ ModuleJet actuator series
facilitates cross-profiling on
headboxes with dilution technology.
The combination of the OnQ
Profilmatic control software andSeparate, protected installation of the electrical units.

34“A thoroughly successful upgrade, no profile problems,no downtimes!”
Thomas Ganster, project manager of the OnQ ModuleJet upgrade, Weig Karton

An upgrade of outdated headboxes is possible through asimple rebuild.

31 I 2010 I Voith Paper I twogether

REBUILDS“We are impressed by this innovative Voith solution.”
Henning Dippel, KM 6 operations manager, Weig Karton“Although the project was decided on at very short notice, only around five weeks
from placing the order to startup, everything went off without a hitch. Since theupgrade, there has not been a single malfunction in the hardware or software.
We are impressed by this innovative Voith solution.”concept to increase the efficiency ofdated, so that the actuator motors

allows easy rebuilding. The new

the KM 6. In two days of downtime,and distributor boxes were, in part,

actuator system is also practically

employees of Voith Paper and Weig

no longer able to withstand themaintenance and service free. Since

Karton worked together in the field totypical harsh installation conditions

the upgrade of the KM 6, Weig

exchange the 79 actuators and layof a board machine. The aggressive

Karton has achieved a higher overall

the cable. The computer network

environment led to heavy corrosion

availability and thus a significant

and the data connections were alsoof the connection elements of the

improvement in efficiency. Since

inspected and renovated. The

distributor boxes. The operators ofstartup, the system has operated

OnQ Profilmatic hardware andthe KM 6 recognized that, after 10

without a malfunction.

software were upgraded andyears, even the most robust system

connected to the customer’s

would be subject to breakdowns

operating data capture system via

at that spot. The poor accessibility

an OPC link.

of the section at a height ofapproximately seven meters in

Location

The actuator network was

the upper part of the headbox also

Germany

implemented via Ethernet, with anmade the exchange of the actuators

optical fiber connection between the

difficult.

Berlincomputer cabinet and motor control
Mayen
Weig Kartonunit. In addition, an extensive

In order to improve the situation,

replacement parts package was

Weig Karton turned to Voith Paper

put together and an on-call service

in their search for a solution. Based

contract was concluded. This service

on years of cooperation, the partners

Mayen is approximately 30 km west of

ensures that a malfunction will bequickly found a solution approach

Koblenz and is called “the gate to the Eifel”

corrected as quickly as possible.

and agreed on a rapid

because of its location. The city of about

implementation.

18,800 inhabitants is home to companies

Challenge in Mayenin the board industry, engineering, andEconomic results

aluminum and plastic processing.

KM 6 were production malfunctions

The upgrade of the OnQ ModuleJet

Contactthat had occurred repeatedly since

control system on the KM 6 took the2008 as a result of failures in the area

specific requirements of Weig Kartonof the headbox. The system installed

into account, but nevertheless canin 2001 for the cross-profiling of thebe used in many other headboxes.

MasterJet FB headbox was out-

The compact design of the actuator

Pivotal in the modernization of the

31 I 2010 I Voith Paper I twogether

Peter Biener
peter.biener@voith.com

35

REBUILDS

The ScreenFit Doctors are active worldwide. From left to right: May Fursey for North America (may.fursey@voith.com),
Christian Steinmassl for Europe (christian.steinmassl@voith.com) and Gerhard Veh for Asia (gerhard.veh@voith.com).

The ScreenFit Doctors from Voith Paper in action

Operation “Screening Section Optimization”
Avoiding spinnings, paper production with 30% recycled fiber and reducing energy consumption –even seemingly minor improvements, especially in the pulp-screening phase in a stock preparation
plant, can result in major benefits for paper manufacturers. Voith Paper’s “ScreenFit Doctors” areactive worldwide to provide long-term improvements for all screening applications.

36

31 I 2010 I Voith Paper I twogether

REBUILDS

that the rotor was running at its
maximum output. In addition, thecontinual formation of spinnings in
the slot basket significantly reduced
overall screening efficiency. Here,the customer’s requirements were to
improve the machine’s screening
efficiency and reduce its energy
consumption.
Avoiding spinnings
To achieve these goals, Voith
Paper’s Doctors upgraded the plant’s
fractionator with proven C-bar
Screening Technology and a new
MultiFoil rotor. In China, operational
testing by the customer resulted insignificant improvements:
A streamlined MultiFoil blade profile
eliminated the spinning problem.
Also, energy consumption was cut
by 30%, and sticky concentrationsin the accepted stock were reduced
by 50%. As a result of these
improvements, the customer could
save 27,000 euro per year and reduce
CO² emissions by 18.7 tons per year.
Paper production with 30%
recycled fiber
plant’s Metso-Tampella fractionator

assignment was at a board andwas operating with accepted stock

In this example, because of market

packaging plant in southern China.

that had an extremely high sticky

conditions in USA, the customer was

The initial analysis revealed that theconcentration of 7,300 mm²/kg andrequired to use between 10% and   

154

7,300

150

8,000

106

6,000

100

3,891
4,000

50
0

2,000
  
       

0,000    

10,000200 The ScreenFit Doctors’ first
Before rebuild
After rebuild*Method: Ingede

Asia results case study with MultiFoil. The right picture shows a rotor of a non-Voith TLA 450 screen with spinnings at the foil blades.

31 I 2010 I Voith Paper I twogether

37

100

  

250
207

79

80

200
144

150

61

60

100

40

50

20

0




 !  REBUILDS

0 !


Before rebuild
After rebuild*Method: TAPPI(T277 pm-99),
slot width 0.15 mm

North America results case study with EcoRotor and C-bar Q screen basket.

30% recycled fiber in the furnish blend

Reducing energy consumptionof its high-quality papers. As a result,as much as 30%.

the presence of stickies became a

At a LWC paper mill in Germany, themajor problem for the machine, which

ScreenFit Doctors had to reduce theScreenFit − a successful

had been using a three-stage

mill’s energy consumption by 20%

concept

horizontal screening system.

and improve the paper mill’s overall

Here, Voith Paper’s ScreenFit Doctors

output − without compromising theVoith Paper ScreenFit Technologies

quality of the raw stock processing.

offer individually tailored solutions for

replaced the original rotor and bar

a wide range of raw stock screening

screens using 0.2 mm slot width with

When the Voith Paper Doctors arrived,

requirements. The modernization of

EcoRotors and with 0.15 mm C-bar Q

the customer’s DIP tailing screencomplete screening lines, thescreen baskets. In addition, the mill

MST 05/05 was equipped with a

upgrading of equipment from external

upgraded the screening section fromstep rotor and a Contour basket,

suppliers, and the installation of

three stages to five stages, equipping

which was operating with a 4%

innovative products from Voith Paper

stages four and five with new MultiFoil

pulp consistency and a tip speed ofare some of the classic applications

rotors, 0.15 mm C-bar screen baskets,

20 m/s. Here, the ScreenFit Doctors

performed by the ScreenFit Doctors.

and FiberLoop as recovery technology.

installed the newly developed,

Enlarging the screening section andenergy-saving Eclipse Rotor, with ausing this new equipment enabled thestreamlined blade profile. The results

customer to produce quality paper

were convincing: Extensive tests

from 30% recycled fiber. At the sameon the customer’s machine showed

time, sticky removal was improved byenergy consumption cut by 25%

30% and energy consumption was cut

while output simultaneously increasedby 30%.

20%. Additionally, the new rotor

30

100
80

20

60

20

60

15
40

40

10

20
0

 


 


0Contact
Christian Steinmassl
christian.steinmassl@voith.com


   

improved screening efficiency by

Before rebuild
After rebuild*Method: Measurementof resideal on Somerville(TUM242), slot 0.15 mm

Europe results case study with Eclipse Rotor and Contour basket.

38

31 I 2010 I Voith Paper I twogether

PRODUCTS ON SITE

Non-contacting caliper measurement with Voith LSC QuantumSens“Our experience has been impressive”
Mitsubishi HiTec Paper is one of the“Our experience with the new Voith

world’s leading manufacturers of

LSC QuantumSens has been

specially coated grades such as

impressive. This new caliper sensor

carbonless paper, digital imaging

has provided us with true, non-and thermal paper. The company

contacting caliper measurement

required exact caliper measurementthat is accurate and reliable. It hasfor the SM 3 at its German Bielefeld

never marked the sheet, nor has itsite to further increase caliper profiles

been responsible for any breaks.

in the course of a planned process

Our machine operators trust theanalysis. After a long search, Mitsubishi

new sensor and it has given us a

finally found the sole product thatvaluable insight into the quality of

met all its stringent requirements: theour products from coater SM 3.”

Jürgen Heitland,
Head of MSR, Mitsubishi
HiTec Paper Europe
GmbH, Bielefeld Mill.

Voith LSC QuantumSens.

39

PRODUCTS ON SITE

E-Flex – the new generation of press fabrics

Maximum dewatering performancefrom start to finish
E-Flex provides better paper quality, immediate startup of the newly installed press fabric as wellas higher nip dewatering and corresponding dry content. A number of well-known paper manufacturers are using the structurally optimized felt in their presses to achieve these benefits.

It was the desire for better

pores of the batt structure making

The performance of E-Flex remains

surfaces for high-quality board

them more homogeneous. An

constant over its running time. The

grades that spurred the Research

extremely high contact surface toresult is constantly high dewateringand Development department to

the paper web is the result. This alsowith corresponding dry content.

reconsider the structure of press

controls uniform transmission of

And since the added polymer

felts. The result is E-Flex, apress loading in the nip. The

particles give the felt structure long-

breakthrough in the position-specificintegrated polymers perfectly bindlasting elasticity, longer running

design of press felts. The dewatering

the batt fibers and thus prevent

times can be attained, compared

performance is provided from theabrasion-related fiber losses. The

to standard felts.

beginning, due to the extremely

felt surface is preserved, pressure

uniform surface structure of the felt

transmission is uniform and there

So, with E-Flex, the operating

and the associated pore volume

is an extremely large contact surface

lives in the test position in a board

distribution.

to the paper. Optimizing themachine were nearly doubled in only

microstructure of a felt means lessa short time from the launch. In thecontamination can penetrate it.

case of a fast-running graphic paper

Cleaning with high pressure showers

machine, the life was extended byThis is achieved by targeted place-can therefore be carried out at

approximately 25%. The goal of ament of polymer particles, which

reduced pressure, which in turn

33% increase is within reach. Along

keep the felt characteristics constanthelps to preserve the felt surface. In

with an increase in running time, theover the entire running time. The

addition, the porosity and dewatering

improved dewatering performancepolymer treatment penetrates into the

behavior hardly change.

remains in focus. In combination with

Constant performance40

31 I 2010 I Voith Paper I twogether

PRODUCTS ON SITE

suitably optimized polyurethane rollpolymer structure of the felt prevents

newly developed AquaFlow andcovers for the suction press rollwater from flowing back to the fine

SolarFlow polyurethane suction press(SolarFlow), increases in dry content

capillaries of the paper and thus re-roll covers, synergy components wereof more than 1% can be achieved.

wetting it. The structural optimization

created for a highly efficient press

Most papermakers using E-Flexby means of polymers can be worked

section.

report maximum dewatering rates

into various levels of the press felt,

immediately after startup.

depending on the characteristics thatare to be achieved or optimized. Of

Broad range covered

course, the respective press positionor paper grade also prescribes the

These results show that theway a felt is constructed.

structural optimization undertakenwith E-Flex enables it to be used in a

The paper side or the coarse battbroad range of paper manufacturing

layers can be modified with polymer

On Focus: E-Flex

applications. E-Flex thus not only

particles. But this also applies to

ProEnvironment

facilitates improvements inthe basic structures and – if the

ProRunability

manufacturing for special paper or

requirement demands it – to the

ProQualityboard, but also for fast, high-side of the felt not in contact with

ProSpeed

performance graphic machines.

the paper.

The polymer structure with an

The manner in which the polymers

improved rebound capacity ofare placed or applied is extremely

the felt gives stable dewatering

uniform. As the particles do notcharacteristics over the entire

just remain on the felt structure but

running time. The optimally set poreactually penetrate into it, proper

volume controls the flow of water

treatment creates a three-dimensional

into and through the felt to the

network. This gives E-Flex long-press roll cover or shoe press belt.

lasting elasticity – the key to constant

Upon leaving the press nip, thefelt characteristics. Together with theSection: Press
Paper grade: Graphic papers, board,packaging papers
Contact
Peter Mödl
peter.moedl@voith.com

E-Flex in different designs with position-specific polymer structure.

31 I 2010 I Voith Paper I twogether

41

PRODUCTS ON SITE

MultiForm IC – expansion of the I-series

New forming fabric design forboard & packaging paper machines
In the wet end, forming fabrics such as the new MultiForm IC
have a significant influence on the dewatering process and canthus help save raw materials, fibers and fillers. But efficientdewatering also means less energy is required for the drives ofthe fabrics.
After the successful introduction ofMultiForm IC is a new product in

the PrintForm IT and PrintForm IS

the I-Series that was introduced

products for graphic paper machines,

a year ago and was alreadythis innovative product concept is

successfully tested in production

now also being adopted for use

facilities. What MultiForm IC has inwith board and packaging paper

common with PrintForm IT & IS ismachines in the MultiForm IC.

the innovative warp concept in the

The development objectives for the

fabric design.

new MultiForm IC can be summarized
by the following three benefits:

At a ratio of 3:2, more warp yarns
are used on the paper side than ont Improved mechanical fiber

the bottom side.

retentiont Improved paper profile quality
t Reduced energy costs due tolowered drive power

In comparison to modern SSBs
there are several benefits, as shownin the table below.

Advantages of the innovative 3:2 warp ratio of the fabric design
Changed fabric characteristics:

Advantages in paper manufacturing:Higher number of support points on the paper side

Higher mechanical retention, improvement of formation, reduced
fiber carrying

Reduction of yarn diameter on the paper side allows a smaller meshthickness and thus less open volume in the fabricLess water carrying

Larger warp diameters on the bottom side, which allow the use oflarger weft diameters

Higher fabric bending stiffness for higher stability and cross profile
improvement of the paper

Lower warp yarn density on the bottom side enlarges the open
mesh surface on the bottom side

Less dewatering resistance of the fabric increases the dewatering capacity;
vacuums of the dewatering elements can be reduced and can also decrease
the drive power

Offset of the paper-side and bottom-side warps to one anothercreates many small dewatering capillaries in the fabric

Reduction of hydraulic markings

1.

2.

3.

4.

5.

42

31 I 2010 I Voith Paper I twogether

46Competitor 3

Competitor 1

Voith test
MultiForm ICY
2

Competitor 2Competitor 1

Power consumption
Low
High

PRODUCTS ON SITE

8 10 12 14 16 18 20 22 24
Running time [months]

Fig. 1: Records of power consumption at suction
couch roll.

MultiForm

ICY

ICW

IKY

IKW

Product

SSB

SSB

SSB

SSB

Type

CoarseCoarse

Kraft

Kraft

Bonding

2/8 shaft

2/8 shaft

2/4 shaft

2/4 shaft

Weft ratio

2:1

3:2

2:1

2:1

Warp ratio

3:2

3:2

3:2

3:2

Fig. 2: Development planning of the I-series for board andpackaging paper.

Large operating window andperformance also remains good if

board was to reduce the energy costs.

high retention

process parameters are changed,

With the MultiForm ICY, energy

this is known as a wide operating

savings were achieved through lower

Before being used in a production

window in which the fabric design

power consumption at the suction

facility, MultiForm ICY and MultiForm

can be used. Good results and large

couch roll. The high dewatering

ICW forming fabrics were tested

operating windows were achieved

capacity of the MultiForm ICY allows

under various conditions

with MultiForm IC fabrics as became

an operating mode with reduced

on a pilot paper machine. In theclear with the results of the SCT test

vacuums, which led to a reduction

process, various fabrics were used(compression strength). At the sameof power consumption at the suction

on the bottom wire position of atime, between 1.5 and 2.5% higher

couch roll of 22-27%. The comparison

DuoFormer D. The aim of these tests

retention values were attained withwas done during production over

was to check the functioning of theMultiForm IC fabrics.

16 months with SSB fabrics fromnew fabric design depending on

three competitors and the respective

various operating parameters. The

Energy saving with MultiForm IC

new fabric designs were comparedconsideration of three different basis
weights.

with modern weft-bound SSB fabrics

Production of high paper basis

and warp-bound SSB fabrics. If aweights, in particular, requires a highfabric design performs well with aexpenditure of energy. The objective

certain machine setting and thisat a production facility for folding box

          

On Focus: MultiForm IC

MultiForm ICY views

ProEnvironment

MultiForm ICW views

ProRunability
ProQuality
ProSpeed 

Section: Former
Paper grade: Board, packaging paper       

t High wear volume fort High open surface forrunning times that can be plannedt High stability for

reduced risk of damage

31 I 2010 I Voith Paper I twogether

good dewatering capacity

Contact
Matthias Höhsl
matthias.hoehsl@voith.com

t Good ﬁber support forhigh mechanical retention
and reduced ﬁber carrying

43

PRODUCTS ON SITE

Detecting problems in the wire section in good time

OnQ FormingSens increases efficiency at Koehler Kehl
OnQ FormingSens is the first online

OnQ FormingSens has been insensor to enable accurate, repeatable

operation since September 2009 at

and continuous measurement of

Koehler Kehl GmbH, Germany.

water weight in the former using high-Installed in the PM 2, the sensor

frequency microwave technology.

provides reliable data on the thermal

Based on these measurements, apaper produced.

range of optimizations can be realized
in the former, such as savings in“With the continuous measurement

vacuum and drive energy.

of the OnQ FormingSens, we canconduct in-depth analyses of ourThanks to its technical features,processes in the former. This allows

OnQ FormingSens can be used for

us to react to problems in the wire

all former types and paper grades. It

section in good time and thus

also helps to improve the runability

increase the efficiency of the paperof the paper machine and safety at

machine.”

work.

44

Joachim Fuchs,
Deputy Head of Production
PM 2/SM 2, Koehler
Kehl GmbHPRODUCTS ON SITE

Have you heard just how quiet paper machines can be?

Voith dBlocker effectively reduces noise
Faster production speeds and larger plants result in noise emissions that sometimes exceed thestatutory limits. The noise levels around paper machines present the designers of a paper mill withthe difficult task of developing efficient noise protection measures. Voith’s new dBlocker effectively
dampens the noise in machine and production halls and can be installed without impacting the
production process.
The statutory requirements on
workplace safety, in particular, (seeseparate information section “EUnoise directives”) mandate technicalor organizational measures to reducenoise. The main sources of noisefrom a paper machine are generally
the suction rolls of the wire and press
sections. With very high broadfrequency sound levels of around 95
to 105 dB(A), they produce a very
unpleasant noise. Because this iswhere most of the noise comes fromthe current focus of the acousticaldesign process is on the wire andpress sections.
Voith dBlocker – the “noise
gobbler”
The basic effect of the Voith dBlocker
is to absorb the airborne soundemanating in the machine hall using
optimized sound-absorbing elements
fixed to the ceiling and walls (Fig. 1).
When sound waves encounter adBlocker element they penetrate
deeply into the absorption bodywhere they convert much of theirenergy of oscillation into heat. Thismeans substantially less soundenergy is reflected back into the hallthan on a smooth or rigid wall or
ceiling, and the noise in the room is
reduced. In particular, the innovative,

31 I 2010 I Voith Paper I twogether

45

PRODUCTS ON SITE

the noise level to be reduced by
up to 3 dB (A) (Fig. 3).
Careful selection of the foil andfabric cover in combination with thefiber material allows the frequencydependent absorption characteristicof the dBlocker to be perfectly
tailored to requirements. Thismeans it can be optimized to thesurrounding sound field and plannedtarget characteristic of the noiselevel.
Correct positioning of dBlocker
elements
The noise from a production facility,

Fig. 1: Fitting dBlocker elements to walls and ceilings.

particularly that from a paper
machine, generally comes frompatented material combination usedcoefficients that are twice as large as

many individual noise sources

achieves exceptionally high acoustic

comparable products available on

and spreads out in the machine

absorption coefficients into the low-

the market (Fig. 2). Generally evenhall. To create the greatest possible

frequency range.

just a few dBlocker elements will

noise-reducing effect with just a

achieve highly audible improvements

few absorber surfaces, the dBlocker

The Voith dBlocker consists of ain the noise level. For example,

elements used have to be installed

combination of different fiber, foil andinstalling an absorber area of lessin the area where the noise sources

fabric materials, providing it on

than 1% of the total PM hall surface

are loudest. The maximum noise

average with sound absorption

area at a paper mill in Austria allowed

zone is usually determined by

Absorption coefﬁcient of test item
130

1.8
1.6
1.4
1.2

      Absorption coefﬁcient [1]2.0Voith dBlocker

1.0
0.8
0.6
0.4

Comparable absorber

8k

Frequency [Hz]Fig. 2: Spectral comparison of sound absorption coefficients.

46

10k

6.3k

5k

4k

3.15k

2k

2.5k

1.6k

1k

1.25k

800

630

500

400

315

250

200

160

0.2
0.0

101
99
97
95
93

Without Voith dBlocker

With Voith dBlocker

91
89
0

5

10

15

20

25

30

35

       

Fig. 3: Reduction of sound pressure level after installationof dBlocker in a paper machine hall.

31 I 2010 I Voith Paper I twogether

40

PRODUCTS ON SITE

means of systematic near-fieldsurface, the dBlocker can also bemeasurements of the sound level

used to efficiently block noise inof all possible noise sources.

damp environments.

Since 2006 lower limits for noise
pollution at the workplace have been

An acoustic camera (Fig. 4) canbe used to accurately analyze the

EU noise directives

Less noise reduces error rate

in force all over Europe. In March
2007 the German government

individual sources of noise from a
Following installation of the dBlocker

implemented the revised EU noiseelements adapted to the specificdirective in a regulation to protect

Once the main sound sources arenoise situation, a significantly

employees from noise and vibration

known, a sound propagation

reduced noise level can be expectedhazards.

calculation of the production hallin the hall and in the vicinity of theis carried out on the basis of the

production facility. As workplace

This directive specifies thatspecified hall geometry. The result

quality and noise exposure are

employers must make hearing

forms the basis for correctly

directly linked, a quieter workplace

protection available from an averagedimensioning and positioning thehas been proven to enhance thenoise exposure of just 80 dB(A).

dBlocker elements.

concentration and performance ofFor 85 dB(A) and above, hearing

personnel exposed to lower levels

protection must be worn. Advice

Cold, heat, water – not aof noise. Even a reduction of 3 dB(A)about noise limits and compliance,

problemwill substantially reduce theas well as possible noise protection

paper machine.

propensity to make mistakes. Less

measures at the workplace, can

The Voith dBlocker was designed

noise is therefore a component ofbe obtained from the employer’s

for a very wide range of ambient

active accident prevention for theliability insurance association,

conditions: for temperatures below

personnel employed.

the occupational health andfreezing but also high temperatures.

safety agency in your country,

When used for example in the dryeror the relevant advisory departments

section, the high-capacity absorberof specialized companies such asretains its excellent acoustical

Voith Paper.

properties. Due to the high level ofWithin the framework of workplacewater resistance in the multi-layer

prevention, noise has a significant
On Focus: dBlocker

role. According to EU estimates,around 60 million workers throughout

ProSavety

Europe are exposed to noise during

ProEnvironmenta quarter of their working hours. In
the European Union noise-induced

Section: Primarily in the wet section;
potential for use in entire
machine hall
Paper grade: Allhearing loss is one of the mostfrequently reported occupational
illnesses.
There are also many similar laws in

Contact

force in Asia and America but they
Harald Graf-Müller
harald.graf-mueller@voith.com

differ in terms of how restrictive they
are.

Fig. 4: Acoustic image of a suction couchroll.

31 I 2010 I Voith Paper I twogether

47

PRODUCTS ON SITE

Balancingweights

Balancingweights

Balancing weights forminimized whip

Patented balancing
element

Fig. 1: Mechanical service components for improved roll balance.

Fig. 2: LunaCoat E provides excellent impact and wear resistance.

Efficiency increase in coating with Luna covers and mechanical roll service

Product combination achieves improved
coat weight profiles
A uniform coat weight profile significantly influences the printability of LWC paper. Profile problems
will result in claims and sales shortfall. The quality of the coating application can be clearly improvedby the utilization of a combined solution of mechanical roll service and Luna roll covers, thus
enhancing the paper quality.
Some paper mills producing coatedvariables by the mill, different solutions

t The paper mill performed several

grades with blade coaters at speeds

were assessed. It turned out that an

TAPIO tests determining that theabove 1,200 m/min have experienced“off the shelf” solution was notfrequency of the variation was very

high frequency coat weight variations

available and a trial and error approach

repeatable and it matched thedue to instability of backing rolls andwould be very expensive as well as

revolution of the coater backing roll.

roll cover combination. Such variations

inefficient. Therefore, the mill decided

Most dominant frequencies werecannot be identified via conventional

to partner with Voith Paper to find a(by amplitude) at one time thequality control systems due to thedefinite solution. A stepwise approachbacking roll rotational frequency.

high frequencies involved – typicallywas taken in which risks were mutually

between 4 and 18 Hz. Depending

evaluated and a forward path was

Product combination as aon the amplitude of coat weightestablished.

solution

Background of the problem

After understanding the root causes

variations, print quality (image
definition) is negatively affected dueof the problem, specific products

to inconsistencies of paper propertiest Printing tests and evaluation of theand services within Voith Paper’s

defect frequency were performed,

existing portfolio were utilized andA paper mill in North America recently

following which it was found thatthe amplitude of coat weight variation

reported such defects. After a verysuch frequency could be traced towas significantly reduced as well as

detailed evaluation of process

MD coat weight variation.

printing quality issues completely

such as ink absorption and gloss.

48

31 I 2010 I Voith Paper I twogether

PRODUCTS ON SITE

eliminated. This combined solution

balancing device (Fig. 1) to improve

involved new LunaCoat backing

balance quality, particularly at theroll covers with improved thermo-

center of the roll where the coat

dynamics and mechanical properties,

weight variation showed the highest

in addition to detailed mechanicalamplitude.

>>> Customer information:t1BQFSHSBEFDPBUFENFDIBOJDBMHSBEFTt$PBUFSUXPTIPSUEXFMMCMBEFDPBUFSTPOMJOF
t4QFFE NNJOt8JEUIN

service on the existing backing roll for
improved dynamic behavior.

Improved paper quality

The LunaCoat series consists of a

After implementing this combined

well-balanced mix of high-value

solution the MD coat weight variation

fibers and functional fillers (Fig. 2).

improved by 60% in the center andThis provides excellent impact

by 40% at the edges (Figs. 3 & 4).

ProEnvironment

resistance, mechanical strength,

This led to improved paper quality

ProRunability

wear resistance and improved

and thus the printability issues were

ProQuality

thermodynamic properties.

resolved.

The scope of mechanical service

Additional benefits were more stable

work included several improvements,

web tension control, improved

e.g. correction of shell thickness

calendering operation based on lessvariation, evaluation of dynamic

coat weight/caliper variability, andconditions of bearings and housings,

enhanced CD coat weight profiles.

On Focus: Combination mechanicalrolls service and Luna roll covers

Section: Coating
Paper Grade: Coated graphic paper
Contact
Sergio Giuste
sergio.giuste@voith.com

as well as examination and correctionof roundness/concentricity of the roll.
One of the tools utilized was a

60.50
0.8

60.00

Backing rolls

g/m2

g/m2

0.6
0.4

Before

59.50
59.00
58.50

0.2

58.00
57.50
0.87 20

0.0
0

4

8

12

16

20

24

28

Hz

60.00
60%

Backing rolls

g/m2

g/m2

60

80

100 120 140 160 180 199.99
Length [m]

40

60

80

100 120 140 160 180 199.99
Length [m]

60.50

0.8
0.6

40

0.4

After

59.50
59.00
58.50

0.2

58.00

0.0
0

4

8

12

16

20

24

28

Hz

Fig. 3: The combined solution for coating – utilization of Lunacovers and mechanical roll service – reduced coat weightvariations by 60%.

31 I 2010 I Voith Paper I twogether

57.50
0.87 20

Fig. 4: TAPIO Time Signal plot showing significant improvement
on total basis weight variation.

49

PRODUCTS ON SITE

Modern Karton relies on close partnership

Clothing, rolls and service from a single supplier
The Turkish paper manufacturer >>> Modern Karton plans to further increase the speed, and thus
the productivity of its PM 3 and PM 4. In order to achieve these goals, one of the largest manufacturersof board and packaging paper in Europe relies on expertise from Voith Paper for clothing, rolls andservice – all from a single supplier. twogether caught up with Şirzat Açikgöz, Operations Manager
Production at Modern Karton in Corlu, Turkey.

“With optimized abrasion and wear resistance wewill be able to extend running times.”Şirzat Açikgöz

Şirzat Açikgöz, Operations Manager Production at Modern Karton (left side) in an interview with Bulent Sendag, Voith Paper, Turkey (right side).

50

31 I 2010 I Voith Paper I twogether

PRODUCTS ON SITE

twogether: What are the productsŞirzat Açikgöz: The installation of

from Voith Paper you have used soa central press roll with thefar, and what were the results?

TerraSpeed thermo-coated roll cover
should lead to better sheet releaseŞirzat Açikgöz: We are currently

and lower draw. With optimized

working on several projects toabrasion and wear resistance weincrease the potential of bothwill be able to extend running times.

machines. At all positions of the
PM 4 forming section, SSB forming

twogether: How can Voith Paper

fabrics from Voith are used. Here,help you to achieve this?

we achieve very good results withregard to runability and service life.

Şirzat Açikgöz: Voith Paper

In the press sections of the PM 3

assists us time and again in finding

and PM 4, we use the MultiFlex V3

solutions, with products perfectly

press felt at most positions. We havealigned to each other, experienced

achieved very good results with thisspecialists and comprehensive

design with regard to stability andservice. This means we canconditioning. And, lastly, Voith fabrics

continuously increase the production

are also used in the dryer section –performance of our machines.

mostly MultiTech LBR spiral fabrics

That’s just the sort of partner weand MultiTech S3.

need for our projects: a single
supplier who understands thetwogether: How do you intend tocomplete picture for each project.

increase the machines’ speed even

We are confident that we will achieve

further?

a lot together in the future.

>>> Info: Modern Karton
The Turkish company Modern Karton is oneof the largest board and packaging paper
manufacturers in Europe. Each year, 700,000 t
packaging paper are produced both for thedomestic market and export markets at the
Corlu location, 120 km west of Istanbul. This
represents approximately 50% of the Turkish
production capacity.
Modern Karton is part of Turkey’s Eren Group.
The company acquired its first paper machine
in 1981. The PM 2 followed 10 years later.
The PM 3 was the first Voith machine, added
in 2001, followed by the PM 4, which started
operation in April 2008. With a width of 8.6 m,
the machine produces testliner grades from
100% recovered paper at 1,500 m/min, withan annual production capacity of 400,000 t.

Contact
Thomas Jäger
thomas.jaeger@voith.com“Voith Paper assists us time and again in finding solutions, with products perfectly aligned
to each other, experienced specialists and comprehensive service.”Şirzat Açikgöz

MultiForm forming fabric.

31 I 2010 I Voith Paper I twogether

MultiFlex press felt.

TerraSpeed roll.

51

NEW TECHNOLOGIES

Fig. 1: 3-D model of the
DeaerationFoamPump 4000.

New development in deinking flotation lowers investment costs

Foam tanks are no longer required due to deaeration pumpWith the new DeaerationFoamPump (DFP) 4000 from Voith Paper, noticeably less space is required forfoam deaeration in the flotation. Previously, the foam tanks in which the foam is deaerated had tostand alone and tended to overflow. The flotation cells also had to be set up on a higher level. These
disadvantages are now a thing of the past with the new foam deaeration pump.
Having a foam tank for primary flotation

As a compact unit, it fully replaces

out of the machine and into theas well as a foam tank for secondary

the foam destroyer, foam tank stirring

subsequent process stage (Fig. 2).

flotation, including stirring units, is now

unit and pump of previous deaeration

becoming superfluous thanks to thesystems (Fig. 4). This means a clear

DFP 4000. The deaeration results are

reduction in investment costs for thevery impressive: The air content of thetank, stirring unit, pipes, pumps andfoam mass is reduced when passing

floor space.

Flotation foamthrough the pump from 80% to an
average of 8%. Conventional deaeration How the DFP 4000 works
addition, by using the DFP 4000,

The foam is conveyed from above

upstream foam destroyers, downstream

into the pump and pre-deaerated

long piping as well as pumps with highby a mechanical foam destroyer. In

head pressures to overcome the floor

the lower part, a quick rotationalheight can be dispensed.

movement is generated whoseAirsystems offer approximately 12%. In
Deaerated
ﬂotation foam

centrifugal forces bring about a52With the DFP 4000, it is possible tosubsequent deaeration. The low-air

deaerate and convey the foam, which issuspension that is generated isloaded with inks and other impurities,

brought to the required pressure so

within a single machine (Fig. 3).

the deaerated foam can be conveyed

Fig. 2: Principle of the
DeaerationFoamPump 4000.

31 I 2010 I Voith Paper I twogether

NEW TECHNOLOGIESThe released air is conveyed out of
the machine on the side through a

Foam deaeration in previous systems

special air chamber so it does not

Flotation as a deinking mechanism isthe air reduces the gas content of

obstruct the foam entering froma proven procedure in which air isthe suspension until the foam

above.

introduced into the recovered paperliquefies and is finally capable ofsuspension. The ink particles andbeing pumped.

The new deaeration pumpother impurities that are to be

in practice

removed, attach to the air bubbles

Until now, deaeration tanks

and are extracted through the foam

always had to be placed underneath

The first DFP 4000 installed at afrom the suspension of recovered

the flotation machine and also

customer site in September 2009

paper. The foam with the dirt

frequently in the cellar of a facility tohas been operating successfully;

particles is subsequently fed toensure a sufficient height difference

other DFPs have since been solddeaeration.

for the conveyance of foam. In

in Europe, America and Asia.
Examinations of the primary foam

addition, the tanks are open on
How does deaeration work?

from the pre-flotation show that the

top and can overflow with excess
foam. That is now a thing of thedeaeration principle performs

In conventional systems, the foam

past with the DFP 4000. The new

outstandingly. The DFP 4000 achieves

is conveyed out of the deinking

pump can be linked directly to thebetter deaeration of the foam thanmachine and into special foam

deinking machine and forms aconventional systems.

tanks. An upstream mechanicalclean and closed disposal system.

foam destroyer breaks up the foamBecause it can be placed at theDue to the success of this new

so that the portion of air upon entry

same level as the flotation cells, thedevelopment, Voith Paper has

into the foam tank is alreadyentire flotation system saves morechanged its standard for flotation

reduced. In the tank, the suspension

space than previous systems. A

systems and in the future will use theis stirred so that the air can escapecellar or an additional floor height

DFP 4000 for which a patent

more easily. The free ascension of

for the flotation is no longer needed.

application has been filed.

Fig. 3:Structure of aconventional
two-stage
flotationsystem.

>>> Operating data:
Inlet air content
Accept air content
Flow quantity
Pressure head
Power input

up to 80%
6-14%
0-6,000 l/min*
2-6 m*
20-60 kW*

Foam
tank

Foam
tank

(*adapted depending on set-up andrequirement)

Contact
Axel Dreyer
axel.dreyer@voith.com
DFP

31 I 2010 I Voith Paper I twogether

DFP

Fig. 4: The
new andnow highly
simplified twostage flotation
system with
DFP 4000.

53NEW TECHNOLOGIESThe “steps beyond cfm” concept opens up completely new ground

Higher efficiency through predictionof dewatering performance
For decades, forming fabric permeability has been specified by
the air permeability value cfm throughout the whole paper machine
clothing sector. This cfm value is firmly established, but nevertheless clearly has limits. Voith Paper has now developed a fundamental
concept, which reveals and eliminates the weaknesses of the cfm
method. The resulting ability to determine the actual dewatering
behavior of forming fabrics is a fundamental innovation in themarket.

Permeability is one of the mostGiven the growing complexity ofimportant properties of forming

modern fabric designs, the cfm value

fabrics. It is directly connected tois becoming increasingly less useful.

the dewatering behavior in the first

This standard procedure based onarea of the wire section. This initial

air permeability does continue todewatering affects, among otherprovide a rough impression of thethings, the initial consistency of thedewatering behavior of a forming

fiber mat and thus also the retention,

fabric, but the method also has clear

formation, and quality. In this way, theweaknesses. The cfm value ispermeability of the forming fabric is ameasured by a stream of air, but indecisive factor for the performance ofthe paper mill, water flows throughthe paper mill. Therefore, one of thethe fabric. Furthermore, there are

primary goals of Voith Paper is tonumerous examples of fabrics thatknow, understand, and predict thecome from different product families

dewatering behavior of forming

and, despite their similar cfm value,

fabrics.

demonstrate very different initial
dewatering behaviors during use in

Currently, the permeability of a fabricthe paper mill.

is indicated by its cfm value. Thisvalue is determined in a standard

New concept gives a deeper

measurement procedure, which has

insight

not changed in the fabric industry in54

decades. The fabric is subjected to a

Although much research has been

specific pressure differential, leading

done in various directions in recent

to a stream of air through the sample.

decades, no satisfactory solution

The resulting speed of the air stream

has been found so far. With “steps

is measured and then identified as

beyond cfm”, Voith Paper has now

the cfm value. The higher the cfm

developed a fundamental concept

value, the more open – or permeable

that completely explains and– the fabric.

eliminates the weaknesses of the

31 I 2010 I Voith Paper I twogether

NEW TECHNOLOGIES

standard cfm method. On the one

quite different. This demonstrates

the flow behavior of almost all

hand, the concept allows to determine

how much the actual dewatering

technical textiles.

the water flow rate through any

characteristics of forming fabrics

fabric. On the other hand, for thefrom various product families differ,

The new concept is used by Voith

first time it is now possible to detect

although they have the same cfm

Paper not only in research, butdifferences in initial dewateringvalue.

it is also applied directly in the

behaviors, even for fabrics with

development and production sites

identical cfm values, and to analyze

Even smaller deviations in design,in Frankenmarkt, Austria, andthem systematically.

for example changes in the weave

Shreveport, Louisiana, USA. Among

pattern or the yarn diameter, canother things, this opens up the

Figure 1 shows the advantage of thesignificantly influence the water

possibility of systematically“steps beyond cfm” concept based

flow rate through a forming fabric.

determining the dewatering

on a flow map. Different areas on the“Steps beyond cfm” uncovers thesecharacteristics of forming fabrics

map represent different dewatering

effects. Additionally, it is now also

and continuously improving them

behaviors. For the forming fabrics

possible to determine the impact of– from the early development stageof several SSB product families, thea change in the water temperature

to the ultimate fine tuning.

associated flow characteristics wereon the initial dewatering.

first determined and then marked
on the corresponding regions of the

The “steps beyond cfm” concept

map. For comparison, the diagonal

relies on the precise interaction oflines and the color coding of thenovel measurement techniques,background indicate the standard

complex simulations, and theoretical

cfm value. Each product family covers

fluid mechanics. Therefore, it is baseda certain cfm range. However, evenon a solid, very general foundation

if various product families partiallyand is neither limited to woven

extend over the same cfm range,

structures nor to forming fabrics.

their positions on the flow map are

Rather, it can be used to characterizeContact
Dr. Christian Iniotakis
christian.iniotakis@voith.com

Fig. 1: “Steps beyond cfm” makes it possible
to distinguish forming fabrics based on theircharacteristic dewatering behavior – even for
identical cfm values. The flow map illustrates
this for several SSB product families.

31 I 2010 I Voith Paper I twogether

55

SPOTLIGHT: TISSUE

13 machines in two years speaks for itself

Tissue producers increasingly opting for Voith Paper
One year after the global financial and economic crisis the tissue sector has again reached arespectable growth rate averaging around 4%. Voith Paper alone has sold 13 tissue machines in thelast two years. This is predominantly due to technologies such as ATMOS, which enable cost-efficientand environmentally compatible production, but also results from product developments like the
NipcoFlex T shoe press.
27.8 million tons of tissue were

the increasing demand in China andaverage growth rate of 3.6%. In

consumed worldwide in 2008, above

Latin America.

China alone tissue consumption willaccount for 40% of this growth.”

all in North America, Europe, Chinaand Latin America. Looking at this

40% of the growth in China
What makes the tissue market so

figure in a 20 year comparison – in1988 it was around 13 million tons –“We assume that the demand for

unique for the industry are the very

one thing in particular stands out:

tissue paper will continue to grow in

different specifications for the paper

Tissue papers have demonstrated athe coming years,” says Rogério

from region to region. Marcus

steady growth rate of more than 4%

Berardi, responsible for sales andSchwier, Vice President Tissue at

per annum. After a lower growth lastmarketing for tissue machines atVoith Paper: “Above all these are

year, the figures expected for 2010

Voith Paper in São Paulo. “Experts

differences in the end product itself,

are promising. This is mainly due toforecast for the coming six years ane.g. the number of plies, or the56

31 I 2010 I Voith Paper I twogether

SPOTLIGHT: TISSUE

softness of the paper, and in market

market with TAD (through air drying)

behavior that varies from country totechnology. This is a technology

country. The opinions and wishes ofthat not only requires a large capital

These kinds of investments are

consumers in this regard often

investment but also entails highalso yielding results for paper

diverge widely. In addition, paperenergy consumption, and thus, highmanufacturers. For example, Voith

manufacturers have to reduce theirproduction costs.

Paper won the order to supply a

production costs, and consequently

Investing in research pays off

turnkey production line for tissue

their use of energy and raw materials,

Since then, Voith Paper has success-paper to Bahrain. The clientin order to stay competitive.”fully countered this technology withcompany is a joint venture between

its ATMOS technology. “It was

the Olayan Group and the Kimberly-

developed in the Tissue Process

Clark Corporation. Other orders

Progress with ATMOS

Technology Center at Voith Paper

come, for example, from Asia Pulp

Against this background Voith PaperSão Paulo. Compared with TAD,

and Paper (APP), YinGe Paper andis pursuing a clear strategy: “Voith is

the ATMOS technology enables

Hengan Paper, who will commission

focusing on concepts that reduce

premium tissue to be produced at aa total of five Voith tissue machines

raw material and energy consumption.

40% lower investment cost, using

in China each capable of producing

We therefore support our customers

60% less energy, fewer fibers and

220 tons daily. In Mexico and Brazil

in operating sustainably. In addition,

also up to 100% recycled or virgin

too, a major tissue manufacturer,

they also benefit economically, as

fibers,” summarizes Berardi.

CMPC Tissue, opted for Voith Paper

our solutions offer low total cost ofwhen ordering two new machines.

ownership,” explains Schwier.

Nevertheless, this technological“Innovative concepts such as

progress, which also represents an

ATMOS rebuilds can be done as

ATMOS and the NipcoFlex T shoe

ecological and economical advancewell. In Chile and North America,press have won over our clients andfor papermaking, did not just happen

customers decided to have

have allowed us to make positiveby accident. Voith Paper’s pilot

rebuilds for their existing machines.

inroads into the premium tissue andmachine in São Paulo is of great“What benefits us significantly in

dry crepe tissue market in the lastinterest for customers and works on

this development is our holistic

three years.”

full capacity. The machine can use

approach, with which we

ATMOS to produce premium tissue

systematically use the synergies

Until 2007, for example, thebut can also manufacture dry crepe

within Voith Paper to the advantage

manufacture of premium tissue

conventional tissue. The pilot trialsof our customers,” explains Schwier.

was generally the realm of those

cover the entire tissue process fromproducers that had cornered thisfiber to finished product.

31 I 2010 I Voith Paper I twogether

57

SPOTLIGHT: TISSUE

Higher tissue production profitability with polyurethane roll covers

SolarSoft increases speed and saves energy
Operational safety, wear resistance, reduced after-hardening, high dry content, press rolls withconsistent performance and low energy consumption – all thanks to SolarSoft. The Solar polyurethane
technology for roll covers has become the leading product for graphic, board and packaging grades.
Compared to conventional rubber roll covers, it offers many benefits to tissue producers.

In 2004, Voith Paper introduced

Productivity improvements

SolarSoft roll cover technology,t Consistent nip pressure with noafter-hardening of the roll

specifically designed for press rolls

SolarSoft increases tissue-making

and suction press rolls on tissue

productivity on a number of fronts:

t Constant sheet moisture profilet Longer grinding intervals and totalt Exceptional dewatering results incover life reduces the machinemachines. Since then, thispolyurethane cover has been
applied many times and is delivering

speed increases or reduction ofmany benefits.

energy consumption

Fig. 1: SolarSoft tissue roll cover.

58

throughout its life

downtimet Optimal vibration absorption

Fig. 2: WebNet technology.

31 I 2010 I Voith Paper I twogether

SPOTLIGHT: TISSUE

The SolarSoft technology’s

Quality is one of the key drivers forsteady-state performancetissue production. The tailor-mademaintains the productivity

SolarSoft surface designs maintain

The cover’s bonding to the shell,

improvement for the life of theconstant nip conditions during

as well as to the functional layerroll cover.

operation, which is essential tois a further benefit of the SolarSoft

maintaining high quality tissue.

cover. With the WebNet technology

Due to the fact that polyurethane isdeveloped in 2009, Voith has set a

not subject to after-hardening,new benchmark. This three-

The toughness and hydrolytic

unlike rubber, crushing issues ordimensional cross linking enables

stability allow for the configuration

irregularities in the CD profile aretotal bonding strength even underof a higher void volume in the niplargely eliminated.

extreme nip conditions (Fig. 2).

Cost savings

The patented bonding system

Exceptional dewatering

Operational reliability

resulting in improved sheet
dewatering capability. The improved
strength of the functional layer

prevents bonding type-specificreduces the level of hole andOffering longer total cover life,

cover failures. The WebNet

groove wear yielding a more

longer running intervals andtechnology avoids debonding of

consistent dewatering over the

reduced grind frequency compared

the cover, minimizing the operator’s

entire life cycle of the roll.

to rubber, overall roll cover

operating risk.

expenditures are lowered fortissue makers. The advantages ofSolarSoft performance

SolarSoft are exponentially
increased when including savings

The polyurethane functional layerfrom reduced energy consumption

has major benefits compared toas a result of efficient dewateringrubber covers. The reason forand drying in the calculation. The

this is the improved key properties

sum of these benefits is a lower

for polyurethane. Polyurethane istotal cost of ownership withmore resistant to chemical wear

SolarSoft compared to rubber rolland abrasion, providing the highest

covers.

hardness and surface stability ofFig. 3: Tissue pressure roll.

31 I 2010 I Voith Paper I twogether

59SPOTLIGHT: TISSUE     

60
1st Run50

2nd Run40 42

3rd Run
4th Run

5th Run

40
37

35

30 31

37

33

32 35
30

28

  
 

20
10
0
0

200

400

 

600

800

1,000

Fig. 4: Comparing the degree of hardness characteristics for rubber andSolarSoft.

Fig. 5: Voith Paper tissue machine.

all roll cover materials. Additionally,polyurethane cover to duplicate

after-hardening throughout the lifeits exceptionally low heat generation

the nip conditions of an existing

cycle of the cover (Fig. 4).

puts significantly less stress on

rubber cover. SolarSoft polyurethane

the bonding layer, while lowering

covers generally soften slightly within

after-hardening effects. This

the first week and then the hardness

enables maximum machine speed,

stabilizes.

and also increases felt life andproduction output.

Applications and results
SolarSoft can be used in all
tissue applications without any

Another key advantage of SolarSoft

problems:

is its resistance to hardening from
Polyurethane and rubber haveoxidative cross linking over time.

different elasticity properties,

Rubber covers will often harden at

therefore they act differently

only 20-40% of their life cycle,

under load. These differences

while polyurethane allows for agenerally require a harderconsistent nip pressure with not Machine speeds up to
2,000 m/mint Roll diameters up to 1,153 mm
t Roll widths up to 6,000 mm
With more than 60 running positions
and 80 deliveries to-date, SolarSoft       

is providing improvements in cover 

 

Suction pressure roll

Improved dryness

Suction pressure roll

Improved dryness; life extended from 6 to 8 months

Suction pressure roll

Speed increase 45 m/min; life extended from 6 to 14 months

Suction pressure roll

Gain of 1% post pressure roll solids

life, machine speed and productquality (Fig. 6).

Fig. 6: Actual tissue machine results
running SolarSoft polyurethane rollcovers.

Contact

60

Suction pressure roll

Improved drying and higher quality edges; speed increase 30 m/min

Suction pressure roll

Speed increase 120 m/min on towel; improved proﬁlePressure rollVibration reduced from 3.6 to 1.7 mm/s

Pressure roll

Yankee steam pressure reduced from 7 to 6 bars

Pressure roll &suction pressure roll

Grinding interval 12 months instead of 6 with any rubber

Kirk Johnston
kirk.johnston@voith.com

Bertrand Gentilhommebertrand.gentilhomme@voith.com

31 I 2010 I Voith Paper I twogether

SERVICE

Mutual trust and cooperation

Smurfit-Stone counts on Total Roll Management
Smurfit-Stone Container Corporation in North America has signed a five-year exclusive agreementwith Voith Paper to provide roll covers, roll grinding and roll mechanical services (Total RollManagement). The goal is to significantly decrease the total cost of ownership regarding rolls
through increased equipment reliability, improved processes and higher product quality.

  

             

Fig. 1: Voith Paper’s Total Roll Management.

   t3PMMDPWFST
t.FDIBOJDBMSPMMTFSWJDFTt3PMMHSJOEJOHt3PMMVQHSBEFTt3FQMBDFNFOUSPMMTt3PMMSFDPSELFFQJOH 4/"3t3PMMUSBOTQPSUBUJPO

Fig. 2: Scope of the TRM program.

In June 2010 Smurfit-Stone started

processes, and gain huge steps

increase process stability and

the TRM (Total Roll Management)

forward in profitability.

product quality.

(USA) paper mill. Implementation

Combining roll service, which

Successful cooperation

at all sites will be completed byincludes all mechanical service andearly 2011. The TRM programroll covers, with Voith Paper’s new

The senior management teams ofshows perfectly how to reduce

generation of press fabrics offers

both companies have made a strong

service costs, improve internal

further powerful ways to save costs,

commitment to the program to ensure

program at its Hodge, Louisiana“Voith Paper with its Total Roll Management program isthe best and most cost-effective partner ...”David Barnett, Director Reliability Center of Excellence“In June of this year we entered into a TRM agreement with Voith for all 12 of our mills in the US and Canada.
We are not focusing on price, but on the total operating costs. We want to bring them down – for this, Voith
Paper with its Total Roll Management program is the best and most cost-effective partner.”

31 I 2010 I Voith Paper I twogether

61

SERVICE

its success. Voith’s TRM programat >>> Smurfit-Stone is managed
by a dedicated strategic accountcoordinator who is responsible for the
implementation, rollout, deliverables
and continuous improvement
process. Mutually agreed-uponprojects have been outlined bymachine and mill level personnel
and will serve as the foundation forresource and manpower allocation.
All roll reliability and machine

Fig. 3: Smurfit-Stone Hodge – TRM team.

efficiency initiatives will be monitored
and directed by the Smurfit-Stone
Operation Excellence team.

t Cost reductions by lowering total
uncoordinated individual measures

Total Roll Management

Contact

operating costs, rather thant Productivity measured by machine-

Mark Hines
mark.hines@voith.com

specific uptime targets andVoith’s Total Roll Management
platform focuses on threecornerstones:

operational improvementst Reliability with guaranteed andproven techniques.

“Voith’s TRM is a critical piece for our mill division to reach our goal of world-class manufacturing. Beyond the very real improvements we see in roll utilization, our mill teams benefit
from learning how to manage through systems, and Voith’s TRM is a world-class system.”Mike Exner, Senior Vice President and General Manager, Containerboard Mill Division                

TRM program commitment value

Improved roll reliability: Increased uptime
and production

Reduction/elimination of unscheduled downtime
due to roll issues

Process optimization and standardization,
benchmarking, optimizing products
and performance

Optimized roll cover solutions: Increased press
solids, improved CD moisture proﬁle, etc.

Increased cycle time between roll servicing

Reduction/elimination of internal
non-core function costs

Improved quality/performance through sheet
consolidation, stability and smoothness

Extended life of wear parts and bearings

Reduction/elimination of scheduled &unscheduled roll-related downtime

Optimize press performance with fabric and roll
integrated solutions

Preventive maintenance and plannedroll changes

Reliable, accurate roll records

Predictable run cycles

Increased roll run time cycles
Increased overall machine efﬁciency
Fig. 4: Total Roll Management.

62

31 I 2010 I Voith Paper I twogether

SERVICE

Forward-looking service extends running times

Innovative roll maintenance saves money
A continuous improvement process is proving to be successful in extending the functional capabilityof the roll. As a result, the number of roll changes will be reduced. One German paper mill is profitingfrom this and has achieved savings of 300,000 euros.
The paper industry suffered severely

scheduled roll changes often did

By necessity, even the practice ofduring the world economic crisis.

not take place and the running times

letting the rolls run until they fail

Maintenance departments wereof the rolls were stretched beyond

found support again in some paper

especially hard hit, having to struggle

their usual capacity.

mills. The costs that arise from roll
failure and the unforeseen stoppage

with budget cuts and changes in theirpersonnel structure. This meant that

The result: a decrease in theof the paper machine associated withpreventive maintenance measures

functionality of the rolls and an

it can be extremely high and –were often reduced. For the most part,

increase in unplanned stoppages.

depending on machine width, speed
and paper grade – can quickly
amount to tens of thousands of>>> Possible monitoring activities:
During machine operation:t7JCSBUJPOBOBMZTJTt#FBSJOHUFNQFSBUVSFNPOJUPSJOHt*OGSBSFEBOBMZTFTPGSPMMDPNQPOFOUTt$PSSFDUTFUUJOHTPGMPBEQSFTTVSFTBOEGMPXSBUFTt5FNQPSBMDPVSTFPGUIFWBDVVN POMJOFNFBsurements in the PCS necessary)t%FXBUFSJOHQFSGPSNBODF JG*%.JTBWBJMBCMF
t$PNQBSJTPOPG1$4JOEJDBUJPOTBOEBDUVBMWBMVFTt-FBLBHFTQPUTt$POUBNJOBUJPOJOUIFPJMTZTUFNt8BUFSDPOUFOUBOBMZTFTJOUIFPJM

During machine downtime:t(FOFSBMJOTQFDUJPOTPGUIFSPMMTVSGBDF
t"QQFBSBODFEFQPTJUT
t4BNQMJOHPGEFQPTJUTBOEMBUFS
laboratory analysist3PVHIOFTTNFBTVSFNFOUTt.FBTVSFNFOUPGTVSGBDFUFOTJPOTt)BSEOFTTNFBTVSFNFOUTt&YJTUJOHHSPPWFEFQUIt/JQ4FOTF
t%PDUPSBOBMZTFT

euros, not to mention theorganizational problems and thestress for everyone involved.
Admittedly, preventive standard
maintenance has its costs too,because rolls or wear-prone parts are
frequently replaced when they could
have been used a little longer.

Roll test stand with
21 test zones.

31 I 2010 I Voith Paper I twogether

63

SERVICE

Roll service excellence.

The likelihood of failure for technical products is usually shown in a diagram that resembles a bathtub, resulting in the name “bathtub curve.”       

FailureTime
Fig. 1: With this approach, the roll is used in thepaper machine until it fails. The result is
unplanned downtime for the paper machine.

64       

Roll running time
so farLikelihood of failure [%]   

Likelihood of failure [%]Likelihood of failure [%]ServiceNew roll running time
Service
Condition analysis

Time
Fig. 2: With the usual preventive maintenance,
the roll is dismantled after a specified period andundergoes standard service including preventive
replacement of any worn parts.

Time
Fig. 3: Voith Paper’s innovative roll maintenance program is based on regular condition
analyses of the roll in the machine, which regularly determine the roll’s continued usability.
The outcome: longer running times without
the risk of a roll crash.

31 I 2010 I Voith Paper I twogether

SERVICE

Limitless: in all dimensions, all roll types and all service work.

Analyzing weak spots in acontinuously monitor the roll during

roll. Through monitoring, a roll’s

targeted fashion

later operation will extend the roll’sfunctional capability and likelihood

running time and give a clear costof failure can be evaluated as

This is where Voith Paper comes

reduction. Therefore, for example, in

illustrated by the so-called “bathtub

in, with innovative roll maintenancethe case of suction press rolls,

curve” (cf. Fig. 1 through 3).

to tackle this difficult area. Througheven running times of 18 months

detailed and systematic condition

are no longer uncommon. Throughanalysis during the service, the rolls

innovative roll maintenance andand their wear-prone parts arecollaboration with Voith Paper, one

thoroughly examined and possible

German paper mill was able to reduce

weak spots are identified. The

its roll maintenance costs for a paper

aim is to find the reasons for themachine by 300,000 euros within one

weak spots and to initiate the rightyear. The previous number of annual

ProSafety

countermeasures. The preconditionroll changes was reduced from 59

ProRunability

for this is that the history of theto 44 in the process. The success of

ProQuality

roll is known, regardless of whether

the concept lies in the continuous

it is a suction roll, deflection

increase of a roll’s safe running time.

On focus: innovative roll maintenance

Section: Total paper machine
Paper grade: Allcompensation roll, spreader rollor rigid roll. Together with precise

No quality whatsoever is lost. Withininspection at a service center,the framework of this innovative rollthis is the foundation for competentmaintenance process, all wear-prone

weak spot analysis.

parts are also checked along with

Contact
Jochen Honold
jochen.honold@voith.com

the roll. Vibrations, temperature andWorking with Voith Paper to target

the surface quality influence theoptimization measures andrunning time and functioning of a

31 I 2010 I Voith Paper I twogether

65

SERVICE

Effective maintenance management with the computerized system from Voith Paper.

Professional maintenance management provided by the system supplier

CMMS – Computerized MaintenanceManagement Systems
For a long time, maintenance task schedules needed to be developed on the basis of experience overlong periods of time. In future, Voith Paper will provide this experience in its computerized maintenancemanagement system (CMMS) already with the delivery of its systems and products. The CMMS thus
supports the maintenance management of the paper mill in daily planning, task documentation andcost control. In addition, management of non-repairable components, wear parts and replacement parts
is improved.
The professional planning of preven-over longer periods. Computerized

available, Voith Paper can of course

tive maintenance is indispensable insystems offer an enormous

also supply the software platform.

ensuring the availability of complex

advantage here.

The CMMS manages inspection
and preventive maintenancemachines, facilities and systems.

66

The goal of higher system availability

Like any CMMS software, Voith

instructions in an object-relatedwith simultaneously lower mainte-

Paper’s solution also manages all

fashion. For this, all relevant areas

nance costs forces maintenancethe system maintenance-relatedof maintenance in the plant aremanagement to constantly optimize

information in a database. The

broken down into so-called

maintenance activities. Reliable key

software preferred by the customer“technical objects.” A typical paper

performance figures are required foror already present in the paper mill,

mill can easily have more thanthis, which make the costs as well assuch as SAP or Maximo, is used for

60,000 technical objects with clear

benefits of maintenance measuresembedding data, instructions andinstructions for preventive

transparent and comprehensible

queries. If no adaptable program ismaintenance.

31 I 2010 I Voith Paper I twogether

SERVICE

KPI: Maintenance costs

Quick access to important
information

60,000 €50,000 €The technical object that is relevant
for maintenance is also linked to thesystem and device data, usually only

40,000 €30,000 €available in handbooks or in warranty
information sheets. The descriptionof the associated maintenance activities

External material costs

20,000 €In-house material costs
External labor costs

10,000 €includes comprehensive information on:t Necessary inspection tasks andIn-house labor costs
0

January February March

April

May

June

July

preventive maintenance actions

t Recommended inspection intervals
t Required time for task performancet Recommended qualification of
executing employee(s)t Required demand of expendable
materials and wear parts

Makes decisions easier: the clearly presentation of maintenance costs in the form of key
performance indicators (KPIs).

professional manner from the very

both the work required and the

beginning, replacement part availability

sources of errors. In this case Voith

can be managed more effectively.

Paper takes over preparation andThrough connection of the CMMS tointegration of data in the CMMS.

the inventory and materials manageDrawing up maintenance plans andment system of the paper mill, theThe tailor-made solutions are

issuing maintenance work orders tocustomer profits from improved

developed in a collaborative effort by

the maintenance personnel is likewisemanagement of expandable materials,

the experienced experts, productdone with this kind of management

wear and spare parts. All relevant

managers, designers and maintenancesystem. Also the contribution of themaintenance activities as well as theirexperts of Voith Paper and Voith

paper-producing personnel in the

resulting costs are routinely analyzed

Industrial Services. The collaboration

mill is used in the consistent imple-

and presented as key performance in-of system engineers and industrial

mentation of “total productive mainte-

dicators (KPIs). These key performanceservice providers offers the paper

nance” principles. That makes all ac-

indicators form the basis for improved

industry new opportunities for more

tivities and the tracking of maintenance management of paper mills’ systemefficient maintenance concepts. Voith

costs for each relevant technical object availability and life cycle cost.

Paper can deliver CMMS solutions astransparent and easy to understand.

part of a new machine or new system

Activity reports are stored in the

Mobile data recording directly

deliveries or as an on-demand service

CMMS in a structured way. Thus, theat the machine

for an existing plant. In cases ofmanagement is able to set up queries

subsequent installation or optimization

throughout the history of a technical

For the most efficient communicationof an existing CMMS, the baseline forobject in a targeted fashion. The result

possible with the maintenanceimprovement measures are

reveals causes behind decreasing

personnel (e.g. service mechanics,

determined by a maintenance audit

performances, and even sneaking

electricians, C&I specialists), the Voith

performed at the beginning of thedeterioration of individual technicalPaper system has the so-called

project.

objects can get detected.

“Mobility4Maintenance” option. With
the aid of mobile recording devices

Effective spare and wear partand RFID (radio frequency identi-

inventory management

fication) technology, the CMMS can beContact
Bernd Stibi
bernd.stibi@voith.com

accessed directly at the machine andSince maintenance-related material

inspection and maintenance orders

consumptions will be tracked in a

can be recorded on site. This reduces

31 I 2010 I Voith Paper I twogether

67

FORUM

High-caliber speakers at panel discussion in Heidenheim“Paper is a medium with a future”
On the panel: five distinguished, highly skilled professionals with five different points of view. Yet in
the end, the consensus was: “Paper is a medium with a future.” The panel discussion hosted by Voith
Paper in Heidenheim was entertaining, enjoyable and provided a forecast of upcoming years.

A quick glance at the podium wasresources of energy, water and fibers?”

print at least as much paper as before

enough to indicate a very exciting

said Dr. Sollinger. In his view, forthe growth of electronic media.”evening event to come at the packed

example, part of this process is using

He had been listening closely to

Heidenheim Congress Center. Thiseven more recovered paper for new

Dr. Sollinger’s opening speech andis where Voith Paper president

paper products. And the Greenpeace

was surprised by one thing above all:Dr. Hans-Peter Sollinger took his

manager agreed that a higher recycling

the rise in demand for tissue paper.

place alongside Greenpeace Germany

quota was exactly what he continues to

However, tongue-in-cheek, he rightcampaign manager Dr. Thomas

demand. “More recycling and lessaway provided his own explanation:

Henningsen to discuss the future

paper consumption – that is the solution “Perhaps the global financial situationof paper. And right away, the twofor ecologically responsible conduct inis bringing more tears to our eyes

embarked on the first dialogue

the paper industry.”that then need to be wiped dry withof the evening – about the endeavors

something soft and fluffy.”

and successes of the paper industry in“But aren’t we already using less andusing increasingly less virgin fiber forless paper thanks to the Internet, etc?”

Increasing demand for

paper production.

asked Angela Elis, German TV editor,

packaging material

author and panel facilitator. The
Responsible use of resources

Returning to the serious issue of theby Thomas Brackvogel, Managing

future of paper, the discussion then“The question in the future will be:

Director of the Neue Pressegesell-

turned to the significance of printed

Despite increasing demand for paper

schaft publishing company locatedinformation in the form of daily andin countries such as India and China,

in southern Germany. “On the contrary,

weekly newspapers, magazines andhow do we deal responsibly with thein our editorial offices we still use andtrade journals. “Naturally these media

TV editor Angela Elis led a lively
discussion.

68

answer to this question was provided

Dr. Michael Knoche, Director of the famous
Herzogin-Anna-Amalia-Library in Weimar.

Sebastian Moleski, President of Wikimedia
Germany.

31 I 2010 I Voith Paper I twogether

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continue to have their place, but
I don’t see them having much of afuture,” interjected Sebastian Moleski.
He was on the panel as president of
Wikimedia Germany, whose bestknown project is the online
encyclopedia Wikipedia.
Just take the example of the
Brockhaus encyclopedia. In a directcomparison the currency of the entries

Five panelists, five points of view, one consensus.

in Wikipedia – which incidentally isused by journalists worldwide as ain Weimar, Germany, which wasfor example, where around 300,000

research tool – could not be betteredfounded in 1691, made the point yet

new releases were showcased, speakor replaced by the printed book.

again that paper, in the form of books,

for themselves, even if individual print“We also shouldn’t forget that in one

is an important cultural asset thatrun sizes are on the decline. Ambitious,

way electronic media even increases

needs to be preserved and cultivated.

well-written literature will always be

paper consumption, namely for“For centuries, knowledge has beenread in book form.”

packaging material.” Those ordering

imparted through books, and I am

from the Internet want to have theirconvinced that this will remain the

Regardless of whether the works ofgoods delivered well packaged.

case in the future, too. What about

the great philosophers are read in

Board continues to be the packaging

the school textbook or the children’s

digital or printed form, or we actuallymaterial of choice.

book? Do you really want to readneed around 350 different daily

a bedtime story from an iPad?”

newspapers in Germany alone, or

Preserve the book as acultural asset

paper consumption will actually rise
Admittedly, he added, there is noas drastically as expected in the next

doubt that certain types of

20 years – “Paper will always have aDr. Michael Knoche offered quite apublications will disappear in thecertain value and importance indifferent perspective on therelentless trend towards using

society.” These were Dr. Sollinger’s

significance of paper. The Director

electronic media. “However, theconcluding remarks, which got to theof the Herzogin-Anna-Amalia-Libraryfigures from the Frankfurt Book Fair,heart of the matter.

Thomas Brackvogel, Managing Director of a
German publishing company.

Dr. Thomas Henningsen, Greenpeace Germany
campaign manager.

31 I 2010 I Voith Paper I twogether

Dr. Hans-Peter Sollinger, President
Voith Paper.

69

FORUM

Voith Turbo’s hybrid gear saves fuelEco-friendly drive alternative for public transit buses
Since the summer of 2010, 22 buses have been driving with the diesel-electric and eco-friendly drive
system DIWAhybrid. At a U.S. bus manufacturer, the DIWAhybrid transmission has been successfully
tested and brought into action. Fuel consumption has been reduced up to 15%, dependingon the route.
The DIWAhybrid is a further develop-

engine when the vehicle is starting andinnovative drive solution, are alreadyment of the proven DIWA transmission

accelerating. During the brake applica-

convinced by the DIWAhybrid-systemand presents a genuine alternative overtion, the asynchronous machine

and have these gears in use.

conventional drives with combustion

serves as a generator andengines in terms of economy andacts as a primary retarderemissions. Simulations and actualthat optimally supplements

measurements have shown fuelthe DIWA secondary retarder.

saving potentials up to 20%. These

This protects the service

are accompanied by a corresponding

brake, reduces brake wear andreduction of CO2 emissions.

minimizes fine dust pollution.

In the DIWAhybrid, an asynchronous

Several bus manufacturers,

electric motor complements the diesel

who were looking for an

Overhaul for machine tools with Voith Industrial Services

Turning old into new after 31 years
Machine tools enjoy a long service life. The machines are made as
good as new in a general overhaul. The retro-fit specialists at Voith
Industrial Services have returned the shine to a 31-year-old drillingmachine.
the guides and clamps are defective“After 60 years a drilling machine

and the electrics are faulty. Several

might be allowed to retire.”wearing parts need to be replaced.
On the reconditioned machine, the70Site manager Michael Maier, withenterprise offers a minimum guarantee

ten years of experience in retro-fitsof one year. “Many workers at ourbehind him, has exact knowledge

customers’ factories prefer to workof every individual volume of thewith the old machines,” says Maier.

First, the machine, which had been inmachine tools. “Once reconditioned,“They are reliable, flexible and easy toservice for decades at an automotive

many of the machines built in theoperate – ideal for daily use at a

supplier’s factory, is collected and1970s can do another 30 years in

production facility.”

completely dismantled. It is found that

service,” explained Maier.

31 I 2010 I Voith Paper I twogether

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German Chancellor visits Voith Hydro

Merkel emphasizes the role of hydro power in Germany
At the end of August 2010, Chancellor Angela Merkel visited Voith Hydro in Heidenheim as part of her“energy tour.” In the company’s “Brunnenmühle” research and development center, she learned about
the current state of the art in hydroelectric power technology.
Voith used the visit to illustrate the

The role of pumped storage plants is

Even in Germany, there is still room

dual relevance of hydroelectric power.

rising in importance in the mix as

for the expansion of hydro power, es-

It is an indispensable technology

electricity generation increasingly

pecially through the modernization offor renewable energy generation

turns to renewable energy sources.

existing facilities. A good example ofand an important storage technology

With them, an oversupply of electricity,

this is the Rheinfelden hydro power

for energy, which contributes toat night for example, can be used toplant on the German-Swiss border,

maintaining the stability of thepump water from a lower to a higher

which Angela Merkel visited just a few

electricity transmission networks

reservoir. At a later time – during

hours before her visit to Heidenheim.

and therefore the power supply.

peak loads or periods of lower wind

It is equipped with four Kaplan bulb

After her visit to Heidenheim, theand sunlight – a pumped storage

turbines by Voith Hydro. The power

Chancellor summed up the positiveplant can provide electricity in just aplant provides clean electricity for

impression she had formed of Voith:

few minutes. This allows for an

about 200,000 households and allows“Now I know that hydro power in

economical use of renewable

for savings of approximately 300,000

Germany is in good hands.”

energies.

tons of carbon dioxide annually.

Hydro power is the most importantsource of all renewable energy.

Wind needs water, solar needs water.

Worldwide, around 80% of renewableenergy comes from hydroelectric
power. A quarter of the electricity
generated by hydroelectric power
is produced with generators andturbines from Voith Hydro.

German Chancellor Merkel visits theVoith Hydro Brunnenmühle laboratory in
Heidenheim.

71

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:
Christina Bauer
Simone Heinrich
Elisabeth Marton
Helena Pirttilahti-Feichtinger
Manuela Zimmermann

External author:
Stefan Küchler

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

Images:p. 5/56 iStockphoto.com
p. 12/13 iStockphoto.com
p. 15
Fotolia.de
p. 30
Josef Gombocz
p. 45
iStockphoto.com
Other images: Voith Paper archive

Paper:The recycled paper RecySatinof this magazine consists of
80% recycled fiber and was
produced on a Voith Papermachine.

December 2010, issue 31

Ident-No. 107508
Copyright 12/2010: No part of thispublication may be reproduced or copied
by any means whatsoever without theexpress permission of the editor.

2

30 I 2010 I Voith Paper I twogether