SUCCESS STORY Europe’s largest new KRAFT paper machine. A PrimeLine MG paper machine for high smoothness and gloss.

PULP & PAPER MILL STORY

ZELLSTOFF PÖLS AG, PÖLS PM2, Gathering impressions – Being part of the Heinzel The Murtal region Group: Zellstoff Pöls AG

The market of Pöls is located in the political of Murtal in the The Heinzel Group is one of the largest producers of market pulp in Austrian federal province of . Central and Eastern Europe.

Ruin of Reifenstein Castle, @ David Bauer Heinzel Group, Zellstoff Pöls AG

The Murtal region, with its main Judenburg, Knit- The Heinzel Group, which is united under the umbrella of Heinzel telfeld, Murau, and Pöls, offers several holiday attrac- PÖLS — KEY FACTS: Holding, ranks together with its subsidiaries Zellstoff Pöls AG and AS tions the whole year round. There is not just the pictur- Estonian Cell and its participation in Biocel Paskov a.s. among the esque countryside for great adventures in summer and • Inhabitants: approx. 2,390 largest producers of market pulp in Central and Eastern Europe. winter, but also Austria’s only Formular One race track • Size: 33.37 km2 — the Red Bull Ring in Spielberg — that attracts high- • Main industries: The Group’s trading division includes Wilfried Heinzel AG, a glob- speed fans as well! pulp and paper production, forestry ally active pulp and paper trading company, and Europapier AG, the leading paper merchant in the CEE region. The Group’s successful The market town of Pöls lies between the south- growth is based on the fulfillment of the highest customer demands ern foothills of the Rottenmanner, Wölzer Tauern and with regard to quality and efficiency. Seckauer Alp mountains in the valley of the River Pöls. Higher peaks in the surrounding area include the Gei- Zellstoff Pöls AG, one of the largest producers of elemental chlo- gerkogel (1,402 m), the Falkenberg (1,158 m) and the rine-free (ECF) bleached softwood sulphate pulp in Central and East- Raningerkogel (945 m). The main industry in Pöls is the ern Europe, is based in Austria, or more precisely in the federal prov- pulp and paper production and the related wood pro- ince of Styria. The Group aims at keeping emissions to a minimum, cessing business. protecting valuable resources, and saving energy. ORION pulp, the brand name under which Pöls pulp is sold, is mainly used to manufacture high-quality printing and writing paper, tissue paper, as well as packaging and special paper.

An integrated paper machine produces bleached kraft paper. This High-speed in the Murtal region at the Red Bull Ring, @ Spielberg, STARKRAFT paper is applied primarily in the production of packaging Erwin Polanc and special applications.

2 3 Paper production at Zellstoff Pöls – Tradition and innovation

The origins date back to 1700. Since then the production site has changed frequently in order to fulfill the technological, economic, and ecological demands of the times.

1700 1921 Prince Ferdinand Schwarzenberg establishes the In 1921, Luigi Burgo & Son, the Italian papermakers from Reifensteiner Paper Mill in the east of Pöls, directly Verzuolo, acquired the mill at a time when financial below Reifenstein Castle. disaster was looming. They were to become the sav- iours of Pöls. The mill was modernized, and Cartiere 1910 Burgo SpA remained a reliable partner who bought Start-up of the first industrial paper machine in Pöls pulp even in economically difficult times. In 1961, the (see picture below). Only five years later, industrial pro- first pulp bleaching facility was installed. duction of pulp began in Pöls. 1984 In 1984, an investment of approx. 250 million USD helped to launch the sulphate production process, raise capacity by 286%, and reduce the environmen- tal load by 766%. Pöls was a pioneer in using oxygen to delignify pulp and reduce chlorine in bleaching by 50%.

1989 — 1998 The paper mill Pöls was acquired by Frantschach AG. The sum of 145 million euros was invested in refining biological wastewater treatment and the bleaching process, as well 3D graphic of the new MG paper machine PM2 as in the installation of a new boiler. Only two years later, a biological wastewater purification plant was built. The move to ECF bleaching technology took place in 1995, and 2012 — START IN A NEW DIMENSION After discussion and the creative input of ANDRITZ’s in 1998, the new recovery boiler no.II started-up successfully. In 2012, the project PM2 was authorized. The start- engineers, a design was finalized that would produce ing point for the new machine was that Zellstoff Pöls machine-glazed (MG) white kraft paper for food pack- “At Pöls, we have a long tradition in paperma- needed to make a strategic decision about how to fur- aging, carrier bags, gift wrapping paper, as well as king, dating back to 1900. With the PM2, we have ther develop the Pöls mill location. industrial, medical, and clinical applications. the latest available technology installed — a real THE PÖLS MILL start in a new dimension.” “The big question for us was what, With the design and details in hand, Zellstoff Pöls in addition to pulp, could we produce signed the contract with ANDRITZ in May 2012. This set Jürgen Rieger Location Pöls, Austria in motion an ambitious plan on the part of ANDRITZ Chief Operating Manager Pöls PM2 that would create or add value?” Zellstoff Pöls and the mill to deliver, install, and start up a complete Products – pulp Bleached softwood kraft pulp ORION Dr. Kurt Maier paper production line by December 2013. CEO Products – paper Bleached kraft paper STARKRAFT 2000 Zellstoff Pöls Capacity – pulp 410,000 t/y In 2000, the Zellstoff Pöls AG was acquired by the 2013 — STARKRAFT PRODUCTION Heinzel Group. Only 5 years later, the “Pöls 500+” project The investment in a new specialty machine might seem On November 10, 2013, the machine was started up Capacity – paper 14,000 t/y on PM1, 80,000 t/y on PM2 for capacity expansion was launched. By 2006, the new difficult to justify. But one having a look at the kraft successfully one month ahead of schedule and is oper- Austria, , , , , Main markets lime kiln with caustification facility was put into oper- paper segment for food packaging and special pur- ating at full speed to produce paper in the range of Eastern Europe ation, followed by the installation of a new container poses leads to a different conclusion. The growth in 28-120 g/m2 for various different end applications. Main customers Paper, sack, and packaging industry tipping facility (2007), a new impregnation tower for these segments is estimated to be 2–4% a year. And, wood chips (2008), and the construction of a new 110 kV unlike publication grades, this segment is not suscepti- The Pöls mill in brief power line (2009) and a new steam turbine (2010). ble to competition from the internet, iPad, etc.

4 5 A STAR IS BORN Europe’s largest new KRAFT paper machine

6 7 Stock preparation and pumps – Unique application and patented pump solution

For the first time in paper production a gravity table, normally used for pulp thickening, was installed and the headbox pump operates at an impressive 92% efficiency!

With a length of more than 157 m and a antees that there is no fiber loss at any width of 33 m, the new paper machine time, and control of the degassing valve hall is approximately the size of a soccer is incredibly simple (pump running = valve field. The equipment is installed on three open; pump not running = valve closed). levels: Level zero houses the pumps and the two stock preparation lines. NEW APPLICATION In the long-fiber line, ANDRITZ installed OWN PULP FOR PAPER PRODUCTION a gravity table for pulp thickening. The One stock preparation line processes gravity table increases consistency from PM2‘s new generation MC pump with long- fiber pulp produced at the Pöls four to eight percent, allowing Pöls to patented SMARTSEP technology. mill, while the other one is fed with pur- save money by building a smaller stor- chased bales for short-fiber pulp. age tower. Separate refining lines for “We installed the long and short fibers are employed, The Pöls pulp mill produces 410,000 t/y though both use ANDRITZ TwinFlo dou- the MC pump, and is the largest manufacturer of ele- ble-disc refiners. Stock blending is per- switched it on, mental chlorine-free (ECF) bleached formed in the ANDRITZ paper machine softwood pulp in Central and Southeast approach system. and have never Europe. The pulp mill processes two mil- had to give it lion cubic meters of wood each year, HIGH-EFFICIENCY HEADBOX PUMP generally with CO2-neutral production. All centrifugal pumps, including 30 units another thought from the new ACP series, were delivered since then.” A PROTOTYPE’S SUCCESS by ANDRITZ. The headbox pump, the At the Pöls PM2 paper machine, a newly most important pump for PM2, features Siegfried Gruber, developed medium-consistency pump a very high efficiency of 92% and low- Head of Project Engineering, Zellstoff Pöls, about the MC was installed without vacuum pump. It est pulsation to guarantee perfect sheet prototype pump installed at the features an efficiency of 70%, which is formation. pulp line already in 2007. well above industry average. The world- wide first pump of the new MC series was installed at the pulp line in Pöls in 2007 as a prototype and has been opera- tive since then. Since then the MC pump has been continuously updated and the innovative, patented SMARTSEP system was created in order to avoid fiber loss at any consistency and to simplify con- trol. The air is removed from the pump by a separation impeller, and the fibers In the long-fiber line, a gravity table is used for pulp thickening, in order to reduce the volume of the subsequent storage tower. This is a new application removed with the air are returned safely for the ANDRITZ gravity table, which is typically used for sludge dewatering. to the pump at the same time. This guar-

8 9 PrimeLine MG paper machine For high smoothness and gloss

The PrimeLine MG paper machine has the capacity to produce over 1,000 m of high-quality paper, called “STARKRAFT”, per minute and features several technical highlights.

HEADBOX boiler, thus saving energy and improving PÖLS PM2 The PrimeFlow headbox has a lamella the cost efficiency of the drying process. design and dilution water control to ensure Speed 1,200 m/min uniform fiber distribution on the wire. CALENDER Width 5.4 m The compression zone in the Capacity 80,000 t/y FORMER PrimeCal Soft calender consists of a The Fourdrinier section is equipped heated thermo-roll and soft-covered Product kraft paper with the newly developed ANDRITZ multi HV backing roll. This ensures excel- Range 28-120 g/m2 PrimeForm HB hybrid former. The hybrid lent sheet smoothness and density with End bags, shopper, former has a far higher drainage capac- an even cross-direction profile. application gifts, formfill, ity than conventional formers and yields medicine, significant beneficial effects on the sheet REEL flexpack quality, such as improved formation and In the PrimeReel section, the paper is improved z-direction distribution of fines wound onto reels. The turn-up process is Pöls PM2, technical facts and filler. It provides full operational flexi- fully automated. bility and optimized handling. WINDER PRESS The PrimeWinder Arcus Evo, a two drum The press section utilizes a compact, winder, converts the jumbo rolls into the two-nip PrimePress with a shoe press sizes required for the different end uses. module (X-nip technology with HV-Smart Pöls produces rolls with diameters from counter roll) for very gentle dewatering. 700 to 1,400 mm and a width of up to 3,200 mm. PRE-DRYER SECTION Moisture is reduced further in the PrimeDry pre-dryer section that consists of vacuum rolls and web stabilizers for high runability. The pre-dryer section is of single- and double-tier design.

STEEL YANKEE The heart of the paper machine is a true giant, completely made of steel. A diameter of 6.7 m, a shell length of 6.25 m, and a weight of 150 t make the PrimeDry MG steel Yankee at Pöls the world’s largest. Read more about this unique concept on page 15.

YANKEE HOOD PrimeFlow SW headbox and forming section with PrimeForm HB hybrid former in the new The PrimeDry hood is steam-heated PrimeWinder Arcus Evo and PrimeReel section: The reel’s primary arm is equipped with paper machine (PM2) at Zellstoff Pöls. (160° C) using energy from a biomass spool weight compensation, and the whole turn-up process is fully automated.

10 11 Pöls PM2 MG paper machine – The highlights in brief

The PrimeLine MG paper machine is designed for speeds of up to 1,200 m/min. With a working width of 5.4 m, it produces 80,000 t of kraft paper per year. “Pöls wanted to produce a variety of grades on the same machine. The wish was for a machine similar to PM1, but with a capacity over five times higher and with the ability to produce grades for a broader customer base. The num- ber and type of grades was one of the biggest design challenges from the very start. They required an extremely agile machine, it had to be able to switch grades in an instant to minimize waste and keep PrimeForm SW PrimePress PrimeDry Hood PrimeDry MG PrimeCal Soft machine efficiency high. A great Fourdrinier former for Compact two-nip press Steam heated MG hood Record size steel Yankee: Soft nip calender with value is placed on being able to excellent paper quality arrangement with shoe with 160° C temperature. 22 ft. diameter, 6.25 m multi HV technology for meet customer demand without and paper uniformity press module for high Energy from biomass boiler shell length. Efficient superior smoothness building excess inventory.” nip loads drying with steel Tomas Nölle Vice President of Paper and Board Systems ANDRITZ

PrimeDry PrimeDry PrimeFlow SW PrimeForm HB Pre-dryer section with single- and dou- After-dryer section with PrimeReel PrimeWinder Arcus Evo Headbox with lamella Hybrid former for excel- ble-tier drying groups, equipped with double-tier drying group, Fully automated turn-up Unwind station and two drum technology and consis- lent formation with opti- vacuum rolls and web stabilizers for vacuum rolls, and web process for diameters up winder for excellent winding tency profiling system mal dewatering high runability stabilizers to 3,000 mm results and high speeds

12 13 PrimeDry Steel Yankee – The world’s giant

ANDRITZ was the only supplier able to manufacture and deliver the cen- terpiece of the Pöls PM2 with these dimensions: 6.7 m diameter, 6.25 m shell length.

A diameter of 6.7 m, a shell length of WHEN TWO BECOME ONE 6.25 m, and a weight of 189 t make the A few days after arriving in Pöls, the steel Yankee for Pöls the largest welded, next and most difficult manufactur- high-precision Yankee in the world. ing step for the erection of the world’s largest steel Yankee started. The two MANUFACTURE OF A GIANT halves were placed in front of the new Already during the project phase of this paper machine building, one on top of Manufacturing at ANDRITZ new PrimeLine MG paper machine a the other with millimeter precision, and in unique, and for cast iron Yankees incon- the ANDRITZ specialists from Hungary ceivable, manufacturing solution was and Austria started a very special weld- chosen. To handle the transport over ing technique to assemble the two cyl- narrow roads and through tunnels, the inder halves together. After welding, Yankee was manufactured in two halves the hollow shaft and other components at ANDRITZ Kft. in Hungary and then the were installed into the Yankee in a verti- two halves were delivered to Pöls (Austria) cal position. With the utmost effort, the and assembled on site. At the end of completely assembled steel Yankee, with July 2012, procurement of the materials an overall weight of 189 t, was lifted and High precision in transport began, and right on schedule, after an 8 rotated into the horizontal with the help months manufacturing period including of 2 cranes – one of them with a loading rolling, welding and surface treatment, capacity of 1200 t. Afterwards the steel the two halves were ready for dispatch. Yankee was lifted over the roof into the paper machine building and the already PRECISION TRANSPORT prepared machine framing. The finishing At the beginning of March 2014, the Yan- work on the Yankee, like grinding and kee began its 630 km journey from ANDRITZ metalizing, was then done once in its Kft. in Tisakécske (southeast of Budapest), working position in the paper machine. travelling via Budapest, Nickelsdorf (border crossing between Hungary and Austria), NO LIMITS Vienna Schwechat, Graz, the Gleinalm There seem to be no limits, regard- highway tunnel, St. Michael, and Juden- ing Yankee sizes for production. It is burg to arrive in Pöls. Manufacturing work transport that restricts size and effi- had to be scheduled to allow transport ciency visions. Narrow streets, tunnels, Two become one: at a time that there were no road works as well as transport weight regulations, on-site assembly at Pöls along the route used and where there limit manufacturers in their possibilities. would be no obstructions to normal road ANDRITZ has accepted the challenge traffic. The two halves were transported and with the world’s largest steel Yankee on trucks 22 m long (the two vehicles were it has proven that its logistics concept 6.72 m wide and 4.5 m high). The total really pays off. weight of the loaded vehicles was 224 t. After a three days transport time, the two cylinder halves were delivered safely and PrimeDry Steel Yankee lifted into the machine hall at Pöls. without incident to the Zellstoff Pöls area. Lifting into the machine hall

14 15 Fully automated production process Integrated automation for the Pöls paper mill

The instrumentation, electrification, and automation systems in the PM2 contribute to safe and efficient operation and to the optimum use of nat- ural resources.

For the PM2, ANDRITZ installed the complete con- trol system for the stock preparation plant, the paper machine itself including the winder, and the associated drive and QCS system. The engineering, coordination, and commissioning of automation, electrification, and instrumentation were included as well. Tailored electrification equipment

The control systems were tested in advance in close dried until the plant’s “nervous system” is operationally cooperation with paper experts and the customer him- ready. In short, the control of the mill can mean the dif- self to ensure a fast and smooth start-up. ference between profit and loss.

FULLY AUTOMATED LINE CONTROL REMOTE MONITORING All paper making segments, namely stock prepara- Pöls is served with permanent remote monitoring. The tion, headbox with dilution control, press section per- operators receive continuous assistance during their formance, drying, reeling and winding, are automat- daily work. ically monitored by the system. All sub-systems are integrated into one operator-friendly control interface, OPERATOR TRAINING thus offering comprehensive diagnostic and fault find- In addition, ANDRITZ offers proven solutions for indus- ing while meeting ergonomic requirements. trial training that provide the workforce with realistic, hands-on training modules. COMPREHENSIVE PLANT SUPERVISION The control system touches every piece of equip- The web-based training program provides an effec- ment and instrument in the plant. Nothing is conveyed, tive and measurable form of training for the personnel, ground, classified, pumped, processed, calcined or using pictures, animation, graphics, sound, and text.

View of the control room Fully automated tambour change of the Pöls PM2 MG paper machine that minimizes maintenance.

16 17 For over three hundred years, paper has been pro- stoff Pöls is committed to the prudent use and sustain- The Rhino has landed – duced in the village of Pöls. All these years of expe- able safeguarding of the required natural resources, rience, combined with state-of-the-art technol- other production and auxiliary materials, as well as ogy, lead to a production process and strategy that water, air, and energy. Flexible production based on is based on four pillars: responsibility, sustainability, transparency, and trust. The paper fullfills the end cus- One of the most important resources is wood, a natural tomer requirements, and the new paper machine is product. It serves as the raw material needed to pro- customer needs state-of-the-art technology with maximum energy duce pulp and paper, but it is also first and foremost a efficiency. The product information is prepared to provider of energy. Zellstoff Pöls comprehensively takes ensure that customers know all details at a glance. As the high value creation derived from the material and Zellstoff Pöls has created a symbol for its new PM2, the Flying Rhino, which a privately owner-managed company, Pöls continu- bioenergetic use of wood into account. 95 percent of stands for strength (company and product strength) and flexibility. ally invests in projects that ensure long-term employ- the CO2 emissions arising from the production pro- ment in the region — the construction of the new paper cess consist of biogenic or neutral CO2. This makes a machine is an excellent example. considerable contribution to the avoidance of harm- The Rhino’s ability to fly shows an agility to respond to the grade, delivery, and quality requirements of Pöls’ cus- ful greenhouse gas emissions. Moreover, the paper and tomers. Strong, adaptable, and agile: characteristics that can also be applied to the ANDRITZ PM2 technology. SUSTAINABILITY OF NATURAL RESOURCES board manufactured from the Pöls products is 100% In accordance with the growing awareness of the lim- recyclable and compostable, thus making a decisive ited supply of raw materials and energy sources, Zell- contribution to sustainability. “Holding paper in my hands was a physical “Our message to customers is proof that our hard that we are a strong partner, work and excellent ready to add value whenever cooperation over many white kraft paper can provide a months paid off.” good solution.”

Siegfried Gruber Werner Hartmann Head of Project Engineering Managing Director Zellstoff Pöls Zellstoff Pöls

BAGS GIFTS SHOPPER FORMFILL MEDICINE FLEXPACK STARKRAFT BAGS have been STARKRAFT GIFTS is the all- STARKRAFT SHOPPER is STARKRAFT FORMFILL is the best STARKRAFT MEDICINE is the STARKRAFT FLEXPACK is developed to pack and pro- round paper that suits per- the quality kraft paper paper for automated filling pro- special paper used in the man- used for the packaging tect food items in a natural fectly not only for flowers for shopping bags that cesses and meets all require- ufacture of high-quality medi- of food products. It can and environmentally friendly and presents. Its smooth scores highly with its ments set by the food packaging cal and clinical packaging solu- be printed, laminated, or manner. They protect the surface and high mechan- strength and printability. regulations. The paper is used for tions. It is produced according coated, depending on the high-quality daily life prod- ical strength make it the the packaging of fl our and other to strict quality standards that application and specifi ca- ucts — with each product optimum for end product food products. Nowhere else is are in line with the exclusive and tion required. This pack- having its own requirements. processing. it so important to achieve the very demanding medical pack- aging material is used highest possible strength, guar- aging requirements from the for items such as soups, anteeing high-speed fi lling, with pharmaceutical industry and sauces, confectionery, dairy the lowest possible basis weight. hospitals. products, or coff ee and tea.

18 19 EUROPE ANDRITZ AG Stattegger Straße 18 8045 Graz, Austria p: +43 316 6902-0

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