SupplierS Special Edition November 2009

The magazine for the international pulp and paper industry

Portucel Soporcel: Building the Future

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Special issue ipw – November 2009  SupplierS

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Lennart Nilsson, Holmen Braviken Production Manager, Woodhandling and TMP

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58 Light scattering 56 Light scattering before and after

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2008 - 01-01 2008 - 04-01 2008 - 07-01 New line “ The new line saves 400 kWh/ton”

Holmen Braviken in Sweden is very satisfied with its new 780 ADMT/D TMP line. Compared to the mill’s prior TMP process, energy consumption has been reduced by some 400 kWh/ metric ton. Both tensile strength and light scattering properties have been greatly improved as well, enabling superior print quality.

“We reached well our main goal - saving energy. We also estimate that the payback period will be shorter than expected,” states the line’s production manager, Mr. Lennart Nilsson.

www.metso.com/pulpandpaper  Special issue ipw – November 2009 Editorial

How a dream came true

he new Setúbal PM 4 is the largest and most sophisticated paper machine in the Tworld for the production of uncoated fine papers. The 11.1 m-wide (wire) PM 4 will produce close to 500,000 t/y. This is equivalent to 1,900 t of paper per day or 80 t an hour. In terms of speed, the new paper machine will be able to process 1,800 m/min, corresponding to 30 m/s of paper. It forms the heart of the largest office paper plant in Europe.

The entire Setúbal project has been developed around this massive machine, designed to produce paper with excellent properties in terms of smoothness, printability and runnability. Once running at full capacity, the paper machine will use the pulp pro- duced at the existing pulp mill. A lot of completely new features have been incor- porated, preceded by extensive trials in close collaboration with suppliers. Assembly work on the machine started in Setúbal on January 19th this year, and just the equip- ment contracted from Metso had a weight of 4,000 t. The piping alone represents 700 t, not to mention around two hundred pumps and more than 300 km of cabling.

In other words, this was a huge and ambitious – and arduous – project! The question is, how was it possible that a Portuguese group has achieved this with the precision of a Swiss watch, German punctuality and an adherence to the budget that every nation, especially in times like these, would be proud to claim as one of its characteristic traits? Susanne Haase, Editor in chief The answer is simple: Portucel Soporcel has just picked the best of everything. And it has once again proven that patience is a virtue. The idea of building a new paper machine has been talked about in the company for a long time. However, it was only when Semapa, a Portuguese industrial conglomerate, acquired a majority stake in the capital of Portucel Soporcel in 2004, that this brainchild became reality – indeed not before the financial framework was diligently tied.  ■

And it was Pedro Queiroz Pereira, who, together with his sister owns more than half of the assets of Semapa, pulled the strings. His grandfather, Manuel Santos Mendonça, started the production of sulphate-bleached eucalyptus pulp and his father was the biggest individual shareholder of both Companhia Portuguesa de Celulose and Socel, two companies that were merged to form Portucel in 1976. Pedro Queiroz Pereira is a very modest person and does not want to over-emphasise his role in this context, but in fact he knows that in order to run a business successfully you have to make people dream. And growth is the only way to make dreams come true. That’s why he explicitly underlines that the Group is committed to growth.

Therefore, I am almost certain that we will hear again from this company in the not so distant future. When the next dream comes true …

Special Edition ipw – November 2009  Contents

Editorial How a dream came true 3

Inauguration Official opening in presence of Portuguese President 5

The Chairman Pedro Queiroz Pereira: “We are committed to growth” 6

Interview José Honório, CEO Portucel Soporcel: “We did two remarkable things – stick to the budget and stick to the timescale!” 7

The Project A complex puzzle to work as an integrated system 10

The Project Manager Ângelo Loureiro: “I had a dream” 14

The Company A Group that cares about the future 16 I m p r i n t The Partner AICEP: Coordinator of the negotiations 18 Publishers The Products Sabine Walser Eckhart Thomas Distinctive papers for the international market 20 ■ Editor in chief Suppliers Susanne Haase Tel. +49 (0) 30/29 30 95 15 Metso: Paper machine, calender, winders and wrapping machine, Fax +49 (0) 30/29 30 95 17 air systems and automation out of one hand 22 [email protected] Pöyry: Comprehensive consultancy 24 Advertising manager E.C.H. Will: Installing the world’s largest and widest cut-size Jean-Pierre Ferreira converting equipment 25 Tel. +49 (0) 61 04/6 06-3 56 ABB: Paper machine drive solution for improved productivity 27 [email protected]

Edifer: Outpacing civil construction works 27 Graphic design TM System Finland: Reliable and energy-efficient technology for trim handling 28 Rita Müller Tel. +49 (0) 83 68/91 30 59 MAN Turbo: TURBAIR vacuum systems for extreme flexibility and adaptability 29 [email protected] GAW: Sophisticated starch preparation 30 Publications manager Raumaster Paper: Setting new standards in core cutting 30 Petra Hanke Mota Engil: Execution of piles, earthworks, paving and buried infrastructure 31 Tel. +49 (0) 61 04/6 06-3 60 [email protected] Brunnschweiler: Aerothermic installation and ventilation system 32 Moventas Santasalo: Drive solutions with minimum vibration and noise 32 Publishing company dpw-Verlagsgesellschaft mbH MSK Covertech: Implementing the future of film shrink packaging 33 Borsigstraße 1–3 D-63150 Heusenstamm Rocla: Unique automated warehouse truck concept 34 Tel. +49 (0) 61 04/6 06-0 Fax +49 (0) 61 04/6 06-317 www.ipwonline.de This magazine is printed on one of Portucel Soporcel’s renowned [email protected] paper brands: Soporset Premium Offset in 250 g/m2 (cover) and 90g/m2 (inside pages). Production Central-Druck Trost GmbH & Co. KG Portucel Soporcel production sites (pulp and paper) are ISO 9001, ISO Industriestraße 2 14001, OHSAS 18001 and chain-of-custody certified (FSC and PEFC). D-63150 Heusenstamm

Pictures pages 4, 5, 6, 7, 10, 11, 12, 14, 16, 17, 20, 26, 27, 29, 31, 32, 33, 34: Slides & Bites

 Special Edition ipw – November 2009 inauguration

Official opening in presence of Portuguese President

On 6th of November, the President of Portugal, Aníbal Cavaco Silva, Soporcel group, at an event attended by presided over the official opening of the Portucel Soporcel group’s hundreds of guests drawn from govern- new paper mill in Setúbal. The completion of this investment project ment bodies, public authorities, clients, suppliers and the workforce. Pointing out closes what is regarded as the last window of opportunity for invest- that “we are looking at one of the largest ment in this sector within the European Union. investment projects ever undertaken in Portugal” and that “it offers an example t the end of the ceremony, President and to build up its self-confidence. In for modern industry”, Pedro Queiroz ACavaco Silva awarded the medal of terms of Portugal’s interest, what is really Pereira declared that “there are solutions the Order of Industrial Merit to Pedro important is the contribution this mill will for nearly all the problems (facing Por- Queiroz Pereira, Chairman of the Board make to increasing the productivity and tugal), so let us show the determination of Directors of the Portucel Soporcel competitiveness of our economy inter- needed to put them into practice”. group, and declared that “Portucel is an nationally.” During the ceremony, the paper example and it is examples like this which The President was welcomed by machine, the core element of the new should be held up to help the Portu- Pedro Queiroz Pereira and by José mill, was blessed by the Bishop of Setúbal, guese nation find its course for the future Honório, the CEO of the Portucel Canavarro Reis. Production tests on the machine started on 15 August and operation at full capacity is planned to be achieved in 2011. The machine has demonstrated excellent production capacity and pro- duction speed, in the first 45 days after the start of production tests, has already reached 75 % of the design maximum. The Portucel Soporcel group has recorded extremely positive perfor­  ■ mance, managing to operate a full capa­ city and to increase its paper sales, up by 8.1 % during the first nine months of the year. At the same time, the Group has successfully controlled its costs, which have evolved very favourably over the year. The Group is therefore extremely Visiting the new paper mill: José Honório, CEO, Pedro Queiroz Pereira, Chairman, Aníbal confident of rising to the challenge of its Cavaco Silva, President of Portugal and Carlos Brás, the paper mill manager (from left) new paper mill in Setúbal. ■

Guests assembled before the ceremony Pedro Queiroz Pereira during his speech Pictures: Slides & Bites

Special Edition ipw – November 2009  The Chairman

Pedro Queiroz Pereira “We are committed to growth”

Pedro Queiroz Pereira is the chairman of the board of directors of and weaknesses. But in the last two years Semapa, the group that bought Portucel in 2004. His family owns we have seen some corporations having more than half of the assets of Semapa and Portucel Soporcel, and their own problems, and some family controlled companies making their way he was the one to push the red button for the start-up of the paper a little bit more easily. That’s a fact. But I th machine at 4.30 pm on 15 of August. think this is just a coincidence, not really a question of being better run or better ipw: Was the installation of a new paper- Pereira: I attended that inauguration managed. Besides, family owned compa- making line already in your mind, when when I was a child – just four years old. nies are all different – there are big fami- Semapa acquired Portucel five years I still have vague images of three steps lies and there are small families like mine. ago? that were at the entrance of the build- For instance, the Espírito Santo Bank in Pedro Queiroz Pereira: When we bought ing in my mind. When I visited the plant Portugal belongs to a family with more a 30 % share from the government and again, 50 years later, I recognised these than 300 members and mine just has an additional 30 % from a former share- stairs. However, emotions shouldn’t play two, me and my sister. It depends on so holder, we were committed to develop- a role in investment decisions. many things. I wouldn’t say it’s an advan- ing the strategy of the Group. However, tage to be a family owned company. the strategic plan of Portucel was already ipw: Your father was the biggest indi- There is only one main difference: People to put in place a new paper machine. So vidual shareholder of Companhia Portu- are generally more motivated when they I wasn’t the first one to think about that. guesa de Celulose and Socel, two com- know who is boss or which family is at the But I have helped to create the condi- panies that were merged to form Portucel helm than when they don’t know whom tions to meet the financial needs in order in 1976. However, he was dispossessed they are working for. ■ to develop the strategic plan that was after the revolution in 1974. So the family already in the company. tradition in pulp and paper is obvious. It ipw: The President of the Republic and is interesting to see that two of the cur- the Minister of Economy, Innovation and ipw: So you were more or less ready to rent major paper projects in Europe, the Development attended the official inau- invest 500 million Euro in that project? mill in Setúbal and the new paper mill of guration. What does this day mean for Pereira: I was aware that this was prob- the Palm Group in King’s Lynn, UK, are you? ably the next step but we took our time done by companies with a family tradition Pereira: For me, at my age, this is cer- to validate the project. We also needed in the background. Are they doing better tainly very, very important. This is a very, some time to create the necessary finan- these days? very important milestone in my career as cial conditions to make such an invest- Pereira: Obviously, companies that are an entrepreneur. ment. family controlled and capital companies or publicly owned firms have different ipw: It looks as if the world’s economy ipw: What was your role besides prepar- characteristics and both have strengths has passed the darkest moment. This ing the financial frame? means that your timing, to reach full Pedro Queiroz Pereira Pereira: My role is very simple and very capacity in 2011, is just right. complicated because I’m the one who Pereira: We think we will be in a very chooses the people and I am the one who good position when the markets recover. has to motivate these people. This is easy And we think we will have an increased and complicated at the same time. net profit, which will probably give us the possibility to grow in the future outside ipw: It’s an art to make difficult things of Portugal. look easy … Pereira: … and to have things done ipw: So I understand that right – it would through other people. be possible in the future to grow in pulp and paper outside Portugal? ipw: Your family has a long history in this Pereira: Yes. We are looking into some industry; your grandfather Manuel Santos investment opportunities in Brazil, Uru- Mendonça started the production of sul- guay and Mozambique but we are still phate bleached eucalyptus pulp – the plant studying. However, we are committed in Cacia, a mill that nowadays belongs to to growth, and so that’s part of our job your Group, was inaugurated in 1953. every day. ■

 Special Edition ipw – November 2009 Interview

José Honório, CEO Portucel Soporcel “We did two remarkable things: stick to the budget and stick to the timescale!” ipw: You had the first test runs after 15th important. Then it is a project that will August. This was the date you decided to increase exports, and so produce trade- aim for on 19th October 2007, more than able goods. And this is extremely impor- two years ago. However, the installation tant; it is even more important today than of a new paper production line is an it was two years ago. But even two years enormous task with a lot of unpredictable ago, a project that sells tradeable goods events, and it seems like a miracle that is a project that can live on a global mar- you have been able to be on time like a ket, because it competes with everybody Swiss clock. around the world. José Honório: Yes, and we are very Of course the Portuguese govern- proud of that! I would say for a German ment also tried to keep this investment it is quite natural but for Portuguese in Portugal; the Portuguese government people it is quite a challenge. We decided has one advantage in the sense that we at that time that we should be Germans: are a Portuguese group. So we had a stick to the programme. And we were very professional discussion with the Por- able to do two remarkable things: stick to tuguese government; and, taking every- José Honório the budget, and stick to the timing. thing into account, we decided to go for the investment in a new paper mill, and the European Commission for approval. ipw: How did you achieve that? also to go in the sense that the paper And the European Commission took an Honório: We have very competent mill should be installed here in Setúbal, unexpected length of time to come to a people in the Portucel Soporcel group where we would also benefit from the final decision. This was the most impor- and we set up a project team that was synergies of integrating an existing pulp tant issue. The second was some increase responsible for carrying out this project. capacity production into paper. in delivery times by equipment manufac- The project was discussed on a weekly turers.  ■ basis between all the teams and the ipw: Were you tempted to move to Executive Committee. We also installed another country? ipw: How closely did you follow the webcams on the site; that means each Honório: Yes. progress on the construction site? one of us could simply open the laptop Honório: Very closely: I had a look every­ and see how things were progressing ipw: Which European countries were you day. in the field. And very important was the talking about? full commitment of the entire group that Honório: I don’t want to name the coun- ipw: I imagine that this is a very impor- this project should be a successful one, tries, because the three European govern- tant achievement. and that we had to stick to time and to ments that talked to us were extremely Honório: Of course it is. Especially as budget, because the public assumed so. professional, independent in the sense we are located in a small country on the And so it was a question of delivering that they never tried to say they were western edge of Europe and don’t have, what we have promised to everybody. better than their neighbour or another compared to others, a long tradition in country. But they did their utmost to this industry: Former Papéis Inapa plant ipw: Sounds like: Yes, we can! show what they could bring to the table. started producing paper in 1969 and Honorio: Yes, we can, and yes, we did! Soporcel in 1991 and we are focused on Because a lot of people can but don’t. ipw: By 2006, you were ready to go uncoated wood-free. I think we are the ahead with this project. Why was it post- only major European producer focused ipw: In fact, nowadays a project of such a poned? on just one segment. size is rare in Europe. Honório: We had two situations in 2006 Honório: Indeed, several European coun- that we did not expect. One was that ipw: Maybe that’s the secret of your tries tried to convince us, through their three European governments together success. ambassadors, to set up this new project with Portugal tried to attract our invest- Honório: I don’t know if it is a secret. in other locations than Portugal, because ment and this prolonged the negotiation What I know is that we are extremely it is a very important project in the process. Then we chose Portugal and our focused and very concentrated on our sense that the level of employment is government had to submit our project to business case, and we intend to keep

Special Edition ipw – November 2009  Interview

concentrated that way. So today we say develop this project. We also discussed the paper machine is connected, and that we have four businesses inside the with them some ideas about the project. from there to the grid. Any disturbance Group: forestry, energy, pulp and paper. I think that some didn’t believe that we imported from the grid will automatically Paper is the most visible one, because would put up a new paper mill, and we put the system in island avoiding paper with this new paper mill we will export got very funny comments. I can remem- machine downtime, which by the way, 1.55 million tonnes of paper – once this ber that once I received a phone call from has already occurred twice. paper mill reaches its estimated output someone from the industry saying to me, of 500,000 tonnes. So, we will decrease “You are very brave”. I’m not so sure if ipw: But this independence from the our exports of pulp, because we will the intention was that maybe we were grid won’t be the only advantage from integrate all the remaining pulp that we doing our job or if we were completely the CHP… produce here in Setúbal. out of our minds doing this project. But I Honório: The main reason to install this took it as a compliment. power plant was to get security and ipw: When will you reach full capacity? independence and to hedge against any Honório: I’m not going to tell you that ipw: Were you hit by the financial crisis distortion in energy prices: It is again a because every engineer will tell you that that just occurred in the hot phase of the decision of decreasing the volatility of the learning curve of every machine is a project? the risk. When we look into the consump- different one. What I can tell you is that Honório: We were very lucky. In 2005, we tion of natural gas in Portugal, we are in 2011, if everything goes according to refinanced all the existing debt the Group an important consumer. Owning the CHP what is scheduled, we will be producing had at that time. When we decided gives us another opportunity of having a the total output of 500,000 tonnes. to commit ourselves to this project we direct relationship with the countries that decided that we absolutely must have a are natural gas suppliers for Europe and ipw: You plan to export the output of the very sound financial balance sheet and so we have a broader base of relation- new paper machine outside Europe? since then we have not had any addi- ships in what concerns the gas supply. Honório: Our intention is to sell the tional financial requirements. But this tonnage of the new paper mill without crisis has an impact on market conditions, ipw: However, this plant is only part of affecting the existing business we have as according to the most recent data, a broader energy concept within the in the other paper mills. That’s why, dur- uncoated wood-free market consumption Group. ■ ing this phase of the start-up, we put the decreased by around 15 % in Europe and Honório: We have what we call the production outside Europe. the same amount in the United States, energy basket that is being implemented and of course it is not the best thing to at the three sites we have in Portu- ipw: Can you specify to which countries? launch a new paper mill with a capacity gal, composed of the new CHP here in Honório: No, I can’t. of 500,000 tonnes. What we feel is that Setúbal together with the two new bio- our business model has proven so far to mass power plants under construction ipw: When you started production, you be very resilient, because we continue at Setúbal and Cacia sites and the new had orders for seven weeks. So there are to have an impressive part of our sales steam turbine for the existing biomass already contracts signed and there will be of premium products and mill brands. cogeneration CHP at Figueira da Foz more contracts. site where we also have, associated with Honório: You know, since the begin- ipw: You also installed a new CHP (Com- others, a CHP plant with natural gas. ning, all our paper mills have produced bined Heat Power) plant. Was the new Moreover, we have a biomass cogenera- at 100 % of their capacity. Our business plant started up parallel to the paper tion CHP already in place in Setúbal and model is, in my view, unique and different machine? Cacia, associated with the pulp mills, from others, because it is fundamentally Honório: CHP production started just and the cogeneration with the fossil fuel based on premium products and mill before the production started in the new associated with the older, existing paper brands, because we have shown a very paper mill, so everything is in tandem. In mill in Setúbal. Once these energy basket strong commitment towards the sector order to minimise risks we connected the projects are concluded, we will have a and because we are investing. Moreover, new paper mill to the pulp mill, and this production of electricity that will corre- we have a strong brand reputation at end was very effective during the start-up of spond almost to 5 % of all the electricity users, high quality standards and we are both installations. that is produced in Portugal. constantly promoting our mill brands. The technical concept we have This way, we have been able to develop behind the CHP gives us the highest ipw: When will that be concluded? very good long-term relationships with efficiency of the paper mill reducing Honório: By the end of next year all the our customers. eventual downtime caused by steam or projects will be finalised. energy failures. For steam, the concept ipw: You certainly have involved your contemplates the installation of two simi- ipw: What are you going to do then? customers at a very early stage in that lar groups of the same capacity, and the Honório: We are concentrating on the new project. back-up from the existing pulp mill. For next development step for this Group. Honório: We have involved our custom- energy, the CHP delivery is made in the ers from the moment that we decided to same substation of our property, where ipw: Thank you for the interview! ■

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A complex puzzle to work as an integrated system

That’s how it all started …

The opening of the new paper mill at the Setúbal industrial complex stayed within budget. Investment in the ■ represents a landmark in the history of the Portucel Soporcel group. new paper mill has totalled EUR 550 The heart of the project, the world’s largest and most sophisticated million, with an additional budget of EUR 75 million for the cogeneration paper machine for the production of Uncoated Woodfree (UWF) plant. Tests on the processing sections paper, was started up by the Chairman of the Group, Pedro Queiroz started on July 1st, using paper reels Pereira, on the afternoon of August 15th, and the official opening has from the existing Setúbal mill working just been celebrated in the presence of the Portuguese President at full capacity. In the run-up to the preliminary start-up, commissioning tests and the Minister of Economy, Innovation and Development and a were conducted in April, May and June large number of the company’s customers. for a huge array of equipment, including the principal components of the paper nce an annual capacity of 500,000 would be duplicated. As a result, this machine and complementary equipment, Ot/y has been reached, the Group’s cogeneration plant (80 MW) has two sets the distributed control system, compres- annual paper output will have risen to of equipment: two natural gas turbines, sors, chillers, cold water systems, water 1.55 million t, confirming its position as two boilers and two chimneys. treatment, transformers and electrical the European leader in the production This megaproject has been in study switchboards, as well as connections to of office paper and boosting its already and development since 2002 and marks the EDP power grid for operation of the strong position on the North American a new world record for an industrial unit plant. The co-generation plant, with the market. of these dimensions, bearing in mind the first firing set in late June, was ready to A cogeneration plant is also con- timeline for its completion and the con- provide steam for the scheduled start-up nected to this project. It produces annu- tracts involving almost 80 suppliers, both of the paper machine. ally around 580 GWh and is the biggest national and international, including main The start-up of this industrial unit natural gas-cogeneration plant in the equipment, civil construction, assembly was viewed with considerable excitement country. The new paper machine needs and engineering. This is also the larg- in the international markets. The new 110 t of low pressure steam and six t of est pile work project ever undertaken paper machine (design drive speed 1,800 medium pressure steam per hour. The in Portugal. Each section of this colossal m/min) has certain very special features design for the new cogeneration plant construction has been designed as a and is different from any other machine has in practice meant building a “plant piece in a complex puzzle to function as in the Group, starting with the machine within a plant”. In order to ensure the an integrated system. width (10.4 m) and certain features of reliability of the production process, it Great care was taken from the earli- the equipment which are entirely inno- was decided that all the main equipment est stages to ensure that the project vative. Construction of the new mill has

10 Special Edition ipw – November 2009 The Project

not had any very significant impact on the Group’s other mills, which have been working non-stop with an above-average order book. From the beginning, the orders for paper from the new mill have been assured for almost two months. Straight to the company’s strategy: “To produce what we sell and not to sell what we produce”. The Setúbal complex already con- tained a PCC plant, with a capacity of 50,000 t/y, which has now been expanded to 170,000 t/y: CO2 is supplied to the new plant through a piperack, 600 m long and 1.20 m in diameter. The PCC plant has five new reactors and in addi- tion to using lime as raw material, the system for feeding PCC to the new plant Transporting a chimney section in February also uses carbon dioxide from the lime kilns (fossil) and from the recovery and reels together for transport in each of caters for approximately 31,900 pallets, biomass boiler. Thereby, it is helping to the two transelevators which lift and corresponding to a capacity of 16,600 t. reduce the overall CO2 emissions of the convey the paper reels for transport This store is designed for an anticipated whole production site in Setúbal. A paper and storage. This store has an important inflow of 215 pallets per h, conveyed by machine of this size and with these char- function: it allows the paper machine to nine transelevators which will place them acteristics also requires an integral water produce different paper types non-stop, in the different racks, and an outflow circuit. According to Portucel Soporcel, it irrespective of cutting capacity in the of 320 pallets and per h, assuring fast is almost a closed circuit. processing or despatch sections for the transport of pallets from the store to One of the major innovations in the quantities manufactured. In addition to the despatch area. Pallets are delivered new paper mill lies in the design of the the technical specifications, the criterion to a point approximately 15 m from the robot operated stores for reels and pal- established for this store was to be able loading platform, allowing for up to eight lets, functioning in direct interconnection to absorb ten days’ average output from trucks to be loaded simultaneously when with the despatch section. This solu- the new machine (one complete manu- working at full capacity. tion has drastically reduced the need for facturing cycle) and around twelve days’ The main pieces of equipment in the  ■ the large areas required in conventional output of printing formats from the exist- converting area are three small-format storage. The automated reel store has ing paper mill. cutting machines with an annual capacity a capacity for around 18,540 t of paper The storage facility is extraordinar- of 360,000 t and three printing formats and can store a total of 6,270 reels, ily vast: 28.4 m high, 93.2 m long and (folio) cutting machines (200,000 t/y). All divided into office, offset and customer 42.3 m wide. It is free-standing, with cutting machines are supplied by AGVs reels. The store is equipped to receive/ the actual storage racks supporting the (automatically guided vehicles), using deliver 186/164 reels per h, thanks to the exterior building. Operating downstream laser guidance systems. The system is concept of horizontal storage in frames from processing, the pallet store is also coordinated by the PPMS (production adjusted to the different diameters in use free-standing; with a height of 28.4 m, a planning management system), through and the possibility of grouping several length of 122 m and width of 47.1 m, it communication interfaces created in each piece of equipment. In October 2008, the steel structure was set-up The new paper mill also allows the Group to achieve a strategic goal: incor- poration in paper of all the pulp pro- duced at the Setúbal site. Previously, two thirds of total pulp output was sold on the market (510,000 t). Now, a large piperack measuring 650 m transports the pulp to the new papermaking line. The treatment of pulps and additives is one of the most critical aspects in the operation of the new mill, due to the ground-breaking characteristics of the paper machine. Higher standards had to be met in the preparation of pulp and

Special Edition ipw – November 2009 11 the Project

additives. Moreover, 17 different types of chemical additives are used. Therefore, attention centred on testing the refin- ers and respective pilot tests started in 2008. In all, the new mill has ten refiners. Moreover, in order to obtain a high qua­ lity standard in washing pulp, two presses were acquired for this purpose. Another innovation at the new Setúbal mill relates to the fibre recov- ery filter: 100 % of the process water is filtered and thus more fibre recovered. In addition to the machine and waste screens, screens in the virgin pulp fed to the refiners were installed. They filter the pulp in order to reduce impurities and The futuristic control room to protect the equipment. The new mill is supplied with borehole water, using a have also been adopted for the treat- The whole system uses modern com- decalcification system and sand filters as ment of chemicals and additives, specifi- munication, including engine control and well. Innovative technological solutions cally the filtration of all additives at the instrumentation which meet the Profibus point of addition and preparation of the standard. Milestones salt in a saturation tank. In addition to the In view of the high levels of automa- eucalyptus pulp, this mill is currently sup- tion and efficiency sought, the develop- 2002 – First marketing and feasibility plied with some softwood pulp in bales ment of the information system (PPMS studies for the new paper mill and a 100 % automated bale pulping line and PIMS) for the new mill in Setúbal has 2003/4 – Pilot tests with the potential has been fitted for this purpose. The aim represented a huge challenge for the IS, suppliers of the paper machine is to maximise the efficiency of this high in terms of technical and functional com- 2005 – Strategic study designed to ■ rethink the project speed paper machine at the start, but plexity. The new facility is a model “smart this production tool will be reduced in mill”, in which all the operations are sup- 2007 – Final decision on the paper machine supplier, signing on October the long term. ported and monitored by the information 19th the contract with the Finnish com- Control of an electrical network with system, like the nervous system in the pany Metso Paper and on November power capacity on the scale of the new human body. 2nd with the consulting company Pöyry mill required the best supervision system Right from the signing of the first Forest Industries currently on offer: the SCADA, compliant construction contract, involving earth- January 2008 – Beginning of the con- with standard IEX 61850. The new project works and piling, preparations were struction (piling) of the new paper mill represents a great leap forward, with new made to accommodate the contractors. at Setúbal advantages in terms of energy saving. At peak times, about 1,600 people were February 2008 – Beginning of the This is because of a large percentage working on the site and Portucel Sopor- construction of the cogeneration of variable speed electrical engines that cel can be deservedly proud of the safety plant within the industrial complex of permit gains of 10 to 30 % in efficiency standards achieved. It has been officially Setúbal compared to fixed speed systems. The rated as excellent in accordance with March 2008 – Start-up of the training programme for human resources at processing facilities in the Group’s new the parameters of the ILO (International several levels paper mill are controlled by a dedi- Labour Organisation). All in all, the new September 2008 – Beginning of the cated DCS (Distributed Control System). paper mill project created 350 jobs. ■ assembly of the automated ware- house Producing high quality paper from the beginning 19 January 2009 – Beginning of the installation of the paper machine April/May/June 2009 – Commission- ing stage, all equipment parts and systems are tested for the start-up End of June 2009 – First firing of the cogeneration unit 01 July 2009 – Start-up of the con- verting area, using paper reels from the existing paper mill 15 August 2009 – The new Setúbal paper machine starts production

12 Special Edition ipw – November 2009 SupplierS

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Special Edition ipw – November 2009 13 The Project Manager

Ângelo Loureiro “I had a dream”

ipw: In March 2008, the Prime Minister engineering information for the engi- laid the cornerstone marking the begin- neering consultant to speed up their ning of the construction of the Group’s work for the layout and loads definition new paper mill. Production was started and consequently for the detailed engi- up in mid-August. What was the big- neering to provide drawings for the con- gest challenge during the construction struction. In this particular issue, we were phase? very successful, sometimes with three Ângelo Loureiro: This project, as every negotiations per week, while respecting project, had very particular facts that had the company’s rules. to be taken into consideration. Let me At the same time, before we could give you one example: during the feasi- do anything else, the piling works bility studies, we concentrated deeply on started and it turned out that the driving the technology and lay-out of the new machines were not available in the quan- paper mill but also on all the intercon- tity required. In total we had to make nections with the existing pulp mill for 5,000 piles 20 m into the subsoil due to the supply of pulp and steam as back- the type of soil and because of earth- up, with the extended PCC (Precipitated quake rules. This situation caused some calcium carbonate) plant and with the delay and consequently an overlapping existing effluent treatment plant expand- of the works for the structure of the PM Ângelo Loureiro ing the capacity. The timing of the imple- building and piling. mentation of all these interconnections The progress of the PM building was a certain level of intermediate manage- ■ without disturbing the runnability of the in line with the time schedule and the ment in the structure of the main supp­ existing pulp mill was in fact one of the next milestone was the installation of the liers required an extra effort and coordi- biggest challenges. overhead cranes, required for equipment nation of the subcontractors that made installation. I would like to highlight that their life difficult in performing according ipw: Who was part of the project team at this stage our main objective was to to requirements. Anyway, the main mile- and how was the work organised? allow Metso to start their PM installa- stone was achieved but it did require Loureiro: In order to make sure that such tion by the very beginning of February constant pressure on the contractors in a huge project runs with only minor prob- according to the contract but we were order to keep the delays under control lems, the organisation was based around extremely ambitious and gave the go- and to keep up with the time schedule. experienced engineers who have worked ahead on 19th January. This was really a This was a very difficult period, but this is before in similar projects in the Group. great achievement! also what we are paid for! This resulted in a small but effective team In the meantime, civil works for the of area managers and discipline mana­ converting facilities and robotised ware- ipw: What were the crucial reasons for gers, with contact based on an open door houses started very slowly and required a choosing Metso as supplier for the paper policy, in addition to the formal project lot of energy to catch up the time sched- machine? meetings. Most of the team members ule. Rainy weather is not very common Loureiro: First of all, the full package of had been involved with the PM 1 and in September/October in this region but the paper machine suppliers did include PM 2 projects at Figueira da Foz mill, it did happen affecting the progress of other equipment than the paper machine PM 3 at Setúbal mill, environmental and further civil works for the sheeters’ foun- itself, namely pulpers, winders, rewinder, energy projects in the Group and people dations and causing some delay in the roll wrapper and roll conveyors, and PM from Pöyry. building construction. Those were very screens. In order to minimise the risks tough times arranging for mechanical of the PM concept, we performed pilot ipw: What would be your description of installation starting by the end of Febru- machine tests with both suppliers, and how the construction phase went? ary this year keeping the milestone for both competitors showed up the reliabi­ Loureiro: Nothing is perfect in this world! starting test-runs on the sheeters at the lity of the technical solutions we would There were different periods of time beginning of July. Going back to the PM, like to implement in this project. We also which were very tough and when a lot of it is worth making some reference to the made an evaluation of the package as energy was required to keep things on electricity, piping and instrumentation a whole and at the end of the day the track. From the beginning, the team was contracts. Start-up was very slow, and decision was based on a technical and aware that the purchase time schedule in this respect we thought that, to some economical approach of the full pack- had full priority in order to release the extent, the shortening of personnel at age.

14 Special Edition ipw – November 2009 The Project Manager

ipw: How did the cooperation with Loureiro: I have been working in this paper mill with the installation of PM 3, Metso go? industry since 1970, just after my gradu- and finally the implementation of this new Loureiro: After the decision-making pro­ ation in chemical engineering. During all mill. What else would a paper engineer in cess, we did a lot of pilot tests for detailed these years, I have developed my skills any part of the world like to achieve three technical definitions of the different ele- in different areas of the paper industry, years away from retirement? I can only ments of the paper machine concept, namely engineering, technical assistance sum it up like this: I had a dream! and an RCM (Reliability Centered Main- to sales, projects in general, operations tenance) analysis in order to guarantee management, expansion of the existing ipw: Thank you for the interview! ■ the best solutions. The installation of the paper machine started eleven days before the planned ® TURBAIR ® schedule and the com- TURBAIR® vacuumvacuum system system offers offers numerous numerous missioning phase was Vacuum System ecological and and economical economical advantages: advantages: carried out with a good understanding from both •så2EDUCES Reduces åfreshFRESH åwaterWATER åconsumptionCONSUMPTION åbyBY å99% å parties of the priorities (requires NO NO sealing sealing water) water) of the interfaces between •så%NERGY Energy åsavingsSAVINGS åofOF åbetweenBETWEEN å25 åtoTO å30%, å the different contractors, thanks to to the the high high thermal thermal efficiency efficiency with a common goal to •så 70% åofOF åtheTHE åabsorbedABSORBED åpowerPOWER åcanCAN åbeBE å achieve the stock on wire å RECOVEREDrecovered åbyBY åpassingPASSING åtheTHE åhotHOT åeEXHAUSTxhaust å on schedule. air throughthrough a heat a heat exchanger. exchange The r. The å RECOVEREDrecovered åenergENERGY åycanCAN åbeBE åusedUSED åfor:FOR ipw: Was there outstand- - Heating the PM hood ing cooperation with one -Heating the PM hood å å0RE HEATINGåTHEåPROCESSåWATER or more suppliers you - Pre-heating the process water would especially like to å å3PACE- åheatingHEATINGSpace highlight? Loureiro: It wouldn’t be fair to highlight one or more suppliers with outstanding coopera- tion, since all of them  ■ have done their best to achieve our goals. How- ever, we have learned about what we should do to avoid some errors we made during the selec- tion phase. ipw: How much time do you calculate for the learning curve? Loureiro: Of course this depends on the efficiency figures we are talking about. However, for a global efficiency of 86 % and being conservative, we would say that a three www.manturbo.com year period is required. ipw: What does the fact MAN TURBOTurbo AG AG Schweiz Schweiz Hardstrasse 319 that you have partici- 8005 Zürich,Zürich, SwitzerlandSwitzerland pated in this important TTel.el. +41.+41. 44.44. 278-2211 278-2211 project mean for you per- FFaxax +41+41.. 44. 278-3370278-3370 sonally?

Special Edition ipw – November 2009 15 The Company

A Group that cares about the future

The Portucel Soporcel group tic value added. Portucel Soporcel pro- recorded 3.8 % growth in overall paper is one of Portugal’s strongest duces approximately 92 % of its electric sales in the second quarter of this year brands in international markets power from biomass, and is responsible in relation to the same period in the for around 10 % of the total conven- previous year. It goes without saying and will be Europe´s leading tional containerised cargo handled in the that figures including sales of the new manufacturer of UWF (Uncoated national maritime ports. paper production will only be available Woodfree Paper) when the new So far, with a production capacity next year. mill reaches full capacity. It is of 1.55 million t of paper, considering With the majority of its products already the new paper mill, and 1.35 mil- sold in Europe, the Group has its own also Europe’s largest manufac- lion t of pulp (of which almost 1.1 million sales network, with support structures turer of bleached eucalyptus t are integrated into paper), the Group in the main European markets and in kraft pulp (BEKP) and indeed has generated in 2008 a turnover of more the United States. Over the years, it has one of the largest in the world. than EUR 1,100 million. deployed an extremely successful mill Once operating at full capacity, the brand development strategy which now he company employs more than 2,200 new paper mill will boost the Group’s collectively accounts for roughly 60 % of Tpeople and plays an important role in annual exports by more than 400 mil- manufactured product sales. This strategy the national economy. Even before the lion euros. This will be added to current was leveraged by unique quality and ser­ start-up of the new paper mill, it repre­ annual exports of more than 950 million vice levels and the continuous reinforce- sented approximately 3 % of Portugal’s euros to more than 90 countries over five ment of brand awareness and prestige exports of goods, which, together with its continents, corresponding to approxi- within which Navigator, the world’s best domestic sales, account for 0.7 % of the mately 90% of its paper and pulp sales. selling premium office paper, plays a national GDP. When the new mill reaches And even against the background of the highly prominent role. At the European full capacity, the Group will account for global economic recession and its impact level, the Group is a leading supplier of ■ approximately 4 % of total Portuguese on manufacturing industry, unparalleled bleached eucalyptus pulp to the spe- exports, with a high coefficient of domes- in the sector’s history, Portucel Soporcel cialty paper segment that accounts for

Helicopter view of the industrial complex in Setúbal

16 Special Edition ipw – November 2009 The Company

more than 50 % of its sales. Forests and for manufacturing high quality papers, 900 million for modernising technology its raw material sources are an area and on improving forest management and reducing environmental impact, of of strategic importance for the Portu- practices. which EUR 175 million are channelled to cel Soporcel group, having certified the Industrially, the Group is structured energy production, mostly from renew- woodland assets under its management around three mills, which are located in able sources. All projects will be finalised by the two most acknowledged certifica- Setúbal, Figueira da Foz and Cacia and in the course of next year. ■ tion programmes: FSC (Forest Steward- has the two largest integrated industrial ship Council) and PEFC (Programme for facilities in Europe producing office and the Endorsement of Forest Certification UWF papers for the European graphics Schemes). The Group manages approxi- industry. All mills operate to the high- mately 120,000 ha of land, of which est level of environmental standards as 74 % are eucalyptus plantations and the reflected in the licences held. remaining 26 % are dedicated to various The production processes adopted uses, namely the production of wine, are also exemplary in terms of sustaina- honey, cork and other forest species. bility and energy efficiency insofar as they Furthermore, the partnerships estab- use forest biomass, a renewable fuel, as lished with the WWF (World Wildlife Fund their main source of energy. The Group is for Nature) have resulted in the clas- currently the largest national producer of sification of almost 50 % of its certified biomass energy. Once up and running, its forest assets as high conservation value large-scale capital expenditure projects areas at landscapes level. The Group in the energy sector will allow the Group also plays an important role in prevent- to increase its energy output by 80 % and ing and supporting the battle against the to account for approximately 5 % of all forest fires that regularly affect the coun- power generated in Portugal. try. Moreover, it holds a majority stake As an immediate effect of its energy in Afocelca, a complementary grouping policy, based on a reduction in the use of of sector companies which specialise in fossil fuels, the Group has successfully cut early fire-fighting operations. This com- its carbon dioxide emissions by 45 % over mitment to fire-fighting and prevention the last six years. At the end of 2008, actions made it possible to reduce to less accrued CO2 retention in its woodlands than 300 ha the area burned in 2008 and corresponded to approximately 6.9 mil- to around 400 ha in 2009 (Sep. 30th). In lion t. terms of research and development, the The new paper mill project in Setúbal  ■ Group has a 94% holding in RAIZ – Insti- was developed together with an invest- tuto de Investigação da Floresta e Papel ment programme in the other units in (Forestry and Paper Research Institute), Cacia, Figueira da Foz and Setúbal: The majority of the company’s land is covered with eucalyptus plantations which works on genetic improvements projects currently underway correspond of the eucalyptus, the prime raw material to an investment of approximately EUR

The History

The origins of Portucel Soporcel date back to the 1950s when a team of experts made the Cacia mill a world pioneer with the production of sulphate bleached eucalyptus pulp. Today, half a century later, the Group continues to pursue this capacity for innovation and entrepreneurial spirit. With a view to restructuring the paper industry, Portucel acquired Papéis Inapa in 2000 and Soporcel in 2001, two strategic moves that were decisive in con- solidating the sector in Portugal and which also led to the creation of the Portucel Soporcel group, which today is a worldwide reference. Throughout the years, its firm conviction in the strong potential of the eucalyptus, a tree especially suited to Portuguese climate and soil, has brought further improvements in the production of paper for printing and writing. In 2004, Semapa (a Portuguese industrial conglomerate, listed on the Lisbon stock exchange, with interests in cement, paper and energy, consolidated net profits before minority interests stood at EUR 137.4 million in 2008) acquired a majority stake in the capital of Portucel Soporcel, initiating a whole new cycle for the Group. It consolidated its position on the international markets and in 2006 announced the construction of the new paper mill in Setúbal. Bonelli eagle – a protected species in the company’s plantations Picture: Joaquim Ferreira

Special Edition ipw – November 2009 17 The Partner

AICEP Coordinator of the negotiations

AICEP Portugal Global is a publicly owned business agency dedicated to the development of a competitive business climate which contributes to the globalisation of the Portuguese economy. Its business model is based on a close alliance with Portuguese com- panies, acting as a public sector partner and provider of value-added services, enjoying a fundamental role in providing information, and facilitating the internationalisation process.

ICEP assists, in all aspects, Portu- group is currently Portugal’s third largest Aguese and foreign companies which, exporter and with this investment it will individually or as part of a group, have increase its total production capacity to annual revenues of more than EUR 75 1.5 million t/y. This will strengthen the million, or represent investment projects company’s position as one of the key of more than EUR 25 million. Therefore, players in this industry in Europe and the agency has been working closely with the rest of the world. Horta underlines, Portucel Soporcel, supporting its promo- “This investment, along with the other tional and commercial activities towards investments being made by the pulp and developing exports and its investments paper industry will surely reinforce the in Portugal and abroad. In its role of Portuguese leadership position in the ■ coordinating body for the negotiation of European Market”. Basílio Horta incentives to special regime projects (that Horta acknowledges that the new are submitted to a specific negotiation paper mill, naturally, will have a quite metric aspect of the new mill were opti- procedure), the agency signed in 2006 significant effect on the region. But, “It mised to satisfy the Setúbal bay natural an incentives contract with the company will be even more important in a region requirements.” “About the Future” for their new paper like Setúbal, very sensitive to the eco- AICEP is not only involved in the mill at the Setúbal industrial site. Also, nomic crisis due to the existence of a project in Setúbal, but is also part of a this project was recognised as having very important automotive cluster”, he wider plan being pursued by the Portucel fundamental importance to the country’s says and adds, “It is also noteworthy that Soporcel group. This plan is nearing com- economy and therefore considered as the whole project will comply with the pletion and has involved a total capital PIN, National Interest Project, meaning most demanding environmental stand- outlay of approximately EUR 900 million, that all bureaucratic procedures related ards established in Europe and that the divided between its industrial units in with the project’s licensing were pushed architectural concept as well as the volu- Cacia, Figueira da Foz and Setúbal. ■ through quickly. Basílio Horta, chairman and CEO of AICEP, has followed the progress of the Abbreviations project closely since 2003 and stresses Ill. illustration mm millimetre the importance of the pulp and paper cm centimetre mmol millimole sector’s activity for Portuguese eco- dB decibel MVA megavolt ampere nomic growth: “Being the 4th largest net EU European Union MW megawatt exporter and representing 0.8 % of GDP g gram VAT value added tax m3 cubic metre and 4.6 % of exports, this sector has also h hour ha hectare No. number been continuously increasing its invest- 2 kg kilogram km square kilometre ments in the environment, in compliance km kilometre m2 square metre with the most stringent environmental kW kilowatt t tonne(s) requirements and in CHP, resulting in a kWh kilowatt-hour tds tonne(s) by dry solids very high energy self-sufficiency (92 % l litre t/d tonne(s) per day t/y tonne(s) per year generated by CHP). The imports cover- m metre max. maximum cf. compare with age rate is at about 40 %, contributing mg milligram CTMP chemi-thermo mechanical positively to the country’s balance of pay- MHz megahertz pulp ments”, he said. The Portucel Soporcel

18 Special Edition ipw – November 2009 The Partner

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Congratulations to the «About the Future» Team on the successful start-up of the new PM4 in Setubal. UltraTemp™ MonoTier® II-R AstenJohnson is proud to be a major clothing supplier on this state-of-the-art machine!

AstenJohnson, a Passion for Paper.

FORMING FABRICS | PRESS FABRICS | DRYER FABRICS | SPECIALTY FABRICS | JOHNSON FOILS www.astenjohnson.com Special Edition ipw – November 2009 19 The Products

Distinctive papers for the international market

The new paper mill represents a crucial framework for the compa- ny’s development, as the proper­ ties of the paper the new mill produces are highly valued by the consumers in the core seg- ments where Portucel Soporcel is present: office and graphical. With this new reality, the Group will be able to reinforce its stra­ tegy, based on added value pre- mium products and the develop- ment of lower grammages.

urrently with annual exports in excess Cof EUR 950 million to around 90 countries in the five continents, Portucel ■ Soporcel expects to increase its exports Soporset is one of the Group’s well known offset paper brands to approximately EUR 1,250 million, as the paper output from the new mill is the production chain and the use of the weights, adapted to end-user and profes- destined almost exclusively for the inter- best raw materials and most modern sionals’ needs. national markets technology, have resulted in the wide The graphic paper brands of the The products comply with the chain market recognition as the top European Portucel Soporcel group lead the Euro- of responsibility in all stages, from raw manufacturer of uncoated woodfree pean rankings in different categories of materials, sourced from forests planted papers. the sector, according to the most recent specifically for this purpose, using sus- Within the range of premium pro­ international study aimed at European tainable management practices, through ducts is Navigator, the world’s best selling printers – over 750 interviews in 23 coun- to efficient paper production resulting in premium paper brand in the office paper tries. The conclusions of this study, which a unique product, which is truly ecologi- segment, and others such as Soporset, assesses, among others, quality, prestige cal, biodegradable and recyclable. These Pioneer, Inacopia, Discovery, Explorer, and evolution of the main offset and are important distinctive factors in an Target and Inaset. Navigator is regularly pre-print brands in Europe, point to the international market which is increasingly sold in more than 80 countries, over consolidation of Soporset’s leadership. selective and demanding in relation to five continents, and has been considered The Soporset, Inaset and Pioneer environmental issues. by independent studies as the Euro- graphical paper brands appear in the top The commitment towards the pro- pean brand with the highest perceived 10 positions in terms of brands’ spon- duction of lower basis weight paper is quality and the best brand performance taneous recognition. Soporset is once today one of the most visible aspects (weighted average of technical and mar- again considered the brand with the of the company’s pioneering approach keting attributes). Navigator, Discovery, highest spontaneous recognition and the to environmental issues. The Group has Pioneer, Inacopia, Target and Explorer most widely used offset paper brand by broken new ground in the production are some of the office paper brands the the European graphic companies. and marketing of 75 g/m2 office paper, company offers for professional or home Overall, Portucel Soporcel provides with a quality comparable and in most use. Soporset and Inaset are reference unique printing solutions, through con- cases superior to standard 80 g/m2 office brands in the graphical market, both in tinuous investment and research, towards paper. offset and preprint. The high printing the development of new products and The high levels of machine perfor­ quality of these brands relies on inten- brands which exceed expectations of mance, quality consistency, printing qua­ sive technical tests and market research. modern paper users, whether in the lity and multifunctionality of the papers, All the brands are available in the most office, at home or in the offset printing added to the quality control throughout important and relevant sizes and basis room. ■

20 Special Edition ipw – November 2009 AZ_210x297_V2_GH_7:Layout 1 23.10.2009 09:40 Seite 1

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Congratulations, Portucel Soporcel Group

On behalf of all cut-size converting suppliers, E.C.H. Will and Pemco congratulate the Portucel Soporcel Group on the successful start-up of their production facility in Setúbal, Portugal.

With the widest sheeter in the world and the most efficient and flexible packaging equipment, we look forward to the impressive production figures, which the Portucel Soporcel Group will reach.

As the suppliers and partners in the cut-size converting department, we are committed, today and in the future, to a successful project.

E.C.H. Will GmbH Nedderfeld 100 • 22529 Hamburg - Germany Special Edition ipw – November 2009 21 Tel. +49 40 480940 • Fax. +49 40 48094318 • E-Mail: [email protected] • www.will.kpl.net SupplierS

Metso Paper machine, calender, winders and wrapping machine, air systems and automation out of one hand

Metso’s delivery included a complete state-of-the-art OptiConcept cise nip control and enables very low paper machine line from headbox to roll handling, with related air nip loads. The paper is reeled with an systems and some stock preparation equipment. The company also OptiReel Plus center-driven reel. Instead of controlling just the linear load and supplied an extensive automation package, including a quality con- tension in the roll, as is done tradition- trol system with web-wide non-scanning moisture measurement, wet ally, it uses a third parameter, torque, to end analysers, machine controls as well as runnability and condition control reeling tightness. This parameter monitoring system. is adjusted via the primary and secondary center drives, which also contribute to he OptiFlo II headbox includes tur- section and last dryer group of after dryer a wider nip load control window. Excel- Tbulence generator technology with section double-tier. HiRun 4000, HiRun lent parent roll build-up minimises reel- wedges for a homogeneous slice jet. It 2000, SymRun Plus-runnability systems ing-related losses, improves downstream provides excellent planarity, formation in the drying section guarantee wrinkle runnability, and makes it possible to wind and strength properties. IQDilution Pro free web run with less breaks. Thus, the larger diameter parent rolls. The parent basis weight profiling provides rapid and machine can be operated with high veloc- roll diameter is 3,850 mm. precise positioning, allowing improved ity and the draw difference be optimised. The WinDrum winders are of a new sheet quality and minimal variability. Tail threading in the single-fabric area is design. This model is designed for web Edge flow channels regulate the flow at performed automatically without ropes. widths over 10 m. A lot of effort has headbox edge areas for uniform slice jet The paper is surface sized with a starch been put into the machine dynamics, i.e. flow profile. solution at the OptiSizer to give it the to design the machine to be as stable as ■ The OptiFormer gap former with required surface strength and stiffness. It possible at these widths. This includes loadable blades includes a roll and blade uses an advanced application technology large diameter winding drums, a stiff process which gives stability, runnability with a unique sealing blade to ensure an rider roll beam in both the machine and and dewatering with high-capacity. The even and defect-free film formation at the the vertical direction, and stiff frames. blade geometry ensures quality – particu- higher end of the running speed range. The winders are fully automated, includ- larly formation. The symmetrical dewater- The use of the sealing blade also enables ing butt-joint splicers. The web sepa- ing allows good filler and fines distribu- the required starch circulation amount rating devices of the WinDrum winder tion control. at the sizer to be smaller than with more represent new thinking in web separa- The OptiPress press section includes traditional application concepts. tion to reach performances not possible two straight nips, the first is a press roll High drying capacity and energy effi- before on very narrow webs as well as nip, the second press is a SymBelt shoe cient TurnDry air dryer were inserted wide webs. This is done with the accu- press nip that provides a long dwell- after the OptiSizer. TurnDry is an air rate bows based on Metso linked sec- ing time and a high press impulse. This dryer for simultaneous non-contact web tional rolls and high-precision spreading ensures a good dryness level. Separate turning and drying. The non-contact turn- beams. Even the aligning tools and proc- nips give good profiles; the shape of nip ing is based on the air cushion gener- ess have been redesigned to give more can be easily adjusted without affect- ated between the web and the turning exact bows. ing operation of other nips. The web dryer. The Setúbal PM 4 has a 2-nip The wrapping machine is fully auto- is fully supported when taken through OptiSoft SlimLine soft calender. It effec- mated and realised with the company’s the entire press section to the dryer tively controls the paper roughness level, non-hydraulic principle, which means section. Separate tail threading is not twosidedness and caliper profile. The that all actuators and components that required. The PressRun blow box keeps calender running parameters, load and have traditionally been hydraulic are now the paper web in contact with the dryer temperature can be chosen to maximise either electric gear motor operated or fabric in the draw between the press bulk and minimise twosidedness. This cal- pneumatic. Moreover, the StreamLine and dryer sections. When air is flowing endar utilises the well-known multizone- wrapping machine features optimised out of the blow box, underpressure is controlled technology with innovative wrap material selection to provide effi- created in the area between the blow sliding bearing assemblies. The deflec- cient use of materials, thus improving box and the dryer fabric. This keeps tion-compensated roll has a high number wrapping economy. The fully automatic the paper web in contact with the dryer of individually controlled loading zones conveyor system conveys the paper fabric preventing it from fluttering. The for accurate caliper profiling with imme- rolls from the winders via the wrapping SymRun pre-dryer section / SymDry after diate quality recovery after web breaks. machine to automatic intermediate stor- dryer section include single-tier pre-dryer The self-loading technology means pre- age and further to trailer loading. ■

22 Special Edition ipw – November 2009 SupplierS

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nnn%jpiXc%Zfd Special Edition ipw`e]f7jpiXc%Zfd – November 2009 23 SupplierS

Pöyry Comprehensive consultancy Pöyry acted as the main engineering consultant for Portucel Soporcel’s new paper mill project. The assignment is a continuation of teamwork that goes back many years. The Group and Pöyry have had a long- standing co-operation in a number of important projects over the years. Pöyry’s involvement with Portucel Soporcel includes engineering Nicholas Oksanen, project supervisor services related to the construction of the first paper machine (PM 1) he scope of Pöyry’s consultancy and the second (PM 2) at the factory located in Figueira da Foz. Tincluded complete mill engineering, site services, commissioning and start- pulp mill, maintenance facilities, offices distribution, process electrification, build- up services. The assignment was imple- laboratories and personnel facilities and ing electrification, electrical room design mented as an EPCM (Engineering, Pro- mill logistics. A major tool used for the and installation design. Instrumentation curement, Construction Management) project was the ‘Virtual Mill’, Pöyry’s and automation engineering including project, accommodating the company’s solution for creating, storing, maintain- DCS design, configuration and installa- requirements. From the very beginning, ing, searching and accessing technical tion design, along with network engi- Portucel Soporcel placed Pöyry’s experts information. The Virtual Mill software neering as conceptual and logical design, in its site organisation. consists of different applications, includ- was also provided. During the imple- Pöyry’s involvement started with a ing ProElina, WebPub, 3D modelling mentation phase, Pöyry’s site team sup- new paper mill project feasibility analysis, software and DocHotel. After completion ported the project team in the engineer- which was carried out in 2003. After- of the project, the Virtual Mill tools and data- ing, building construction, installation, wards, the company performed the pre- bases are still useful, enabling an efficient commissioning and start-up phase. Site engineering study for the project in 2004. interface between the engineering servi- manager, civil liaison engineer, scheduler ■ The mill-site layout, department layouts, ce concept and the maintenance system. (installation, commissioning and start-up), and flow diagrams for the main pro­ For the detail engineering, an organi- installation supervisors, commissioning cesses were presented in this study. For sation supported by the Portucel Sopor­ and start-up support (process, HVAC, this project, the front-end engineering cel’s project team was formulated. The mechanical and piping, electrification, study was carried out in 2006. Technical detail engineering team carried out tasks instrumentation and IT services) were descriptions, layouts and flow diagrams, which included engineering manage- located on site. In the peak period during and an implementation plan as well as ment, time scheduling, project standards the commissioning and start-up phase investment costs and risk analysis were and instructions, and secretarial services. (June, July and August 2009), Pöyry’s site developed and analysed. Procurement services as technical enquiry team consisted of 25 specialists. During In September 2007, Portucel Sopor­ specifications and tender comparisons the installation phase, engineering tools cel commissioned Pöyry to update the were also included. The architectural for each discipline were placed on site, technical concept and cost estimate of design included facades and three- enabling the necessary changes in the the above-mentioned front-end engineer- dimensional perspective drawings. In the engineering documents to be updated ing study. In October 2007, an implemen- area of civil and structural engineering, and distributed directly and effectively tation decision was made for the project the Pöyry team carried out the design of by the installation team. The handling of and Pöyry was assigned to start the detail the paper machine and winder founda- documents at site was centralised in a engineering. tions. As for process engineering, tasks common filing system. Pöyry’s mill engi- In conducting its engineering, the included flow diagrams and operational neering documents, as well as those from mill site was investigated. Pöyry also instructions. Furthermore, mechanical suppliers, were uploaded into the DocHo- reviewed the mill site’s connections to engineering was conducted, including tel system, which guaranteed that the the pulp mill, effluent treatment plant, department layouts, three-dimensional latest version of any document was avail- fresh water wells, PCC (filler) plant, power modelling and civil guide drawings. able and easy to distribute to all parties. plant, natural gas line and roll conveying Piping engineering consisted among In addition to the high-quality paper, from the existing mill. Additionally, its other things of 3D design, P&I diagrams, good runnability and efficiency of the engineers carried out the design of the piping arrangement drawings and iso- process, environmental aspects were also bale pulp storage and pulper station, metrics. Pöyry’s experts also provided taken into account in the technology and additive plant, stock preparation, paper HVAC design, which included basic engineering. The energy efficiency, fresh machine, finishing department, paper roll design, calculations and checking of water consumption, effluent load, raw storage, converting, pallet warehouse and suppliers’ detail drawings. In the area material utilisation, carbon footprint and shipping, fresh water supply, extension of of electrical engineering, the company noise level were the key issues in design- the existing effluent plant, changes at the provided expertise on power supply and ing this competitive mill. ■

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Pöyry E.C.H. Will Comprehensive consultancy Installing the world’s largest and widest cut-size converting equipment

Portucel Soporcel took a single-supplier approach in equipping its The relationship between KPL and cut-size converting department at their new mill. The project features Portucel Soporcel was formed years three cut-size converting lines within the cut-size converting area before this project. The Group’s mills currently run eight E.C.H. Will-Pemco supplied by companies of the Körber PaperLink Group (KPL): E.C.H. cut-size lines. The KPL companies’ solid Will, Pemco and W+D-Langhammer. Heading the KPL team, E.C.H. understanding of their partner’s technical Will was also responsible for selecting and arranging sub-suppliers, and marketing needs has led to compre- from paper reel to finished pallet. hensive system solutions that fulfill their sales and marketing requirements. E.C.H. ltimately, the facility’s cut-size con- Integrated Manufacturing Execution Will, Pemco and W+D-Langhammer have Uverting department includes two System (MES) software talks with the increased production through automa- E.C.H. Will high-speed 16-pocket cut-size mill’s production planning system (PPMS), tion – smartly integrating the MES into sheeters, with Pemco dual high-speed helping to maximise productivity and the customer’s existing order and mate- packaging lines and W+D-Langhammer reduce waste by intelligent management rial management – as well as through automatic palletisers. These lines are pri- of the entire converting process. fast changeover times, higher packaging marily for large orders of A4 and letter- “Having begun operation with the speeds and expanded format and pallet size products. The third line focuses on first two lines in September, we are specifications. flexibility and productivity, with an E.C.H. already seeing the benefits of working E.C.H. Will also brought this chal- Will 8-pocket sheeter matched to a with E.C.H. Will,” said project manager lenge to sub-suppliers, to achieve even flexible Pemco packaging line, a bulk Ãngelo Loureiro. “We value not only the higher labeling speeds for pre-printed packaging line and a W+D-Langhammer equipment, but also their expertise and pressure sensitive, thermal printed and high-speed palletiser. service.” top labels (reams and cartons), as well as

 ■

Special Edition ipw – November 2009 25 SupplierS

automated pallet labeling. Capabilities also include ink-jet marking, sheet inser- tion and strapping. “We’re extremely satisfied with the results, and the great efficiency and flexibility these choices afford us,” said Ãngelo Loureiro. “All three KPL companies have delivered on their reputations for looking after cus- tomer needs.” The Portucel Soporcel group sought the most reliable cut-size converting equipment. And the need was met by E.C.H. Will’s 16-pocket cut-size sheeters, each having six double unwind stands with zero-speed splicing, and the ability to produce more than 800 t/d of cut-size paper. Speed reaches 256 reams per minute. First installed at Setúbal, these sheeters are world’s widest (3.48 m). Connected to each sheeter are two The 16-pocket high-speed cut-size sheeter Pemco high-speed packaging lines: Model 39S ream wrapper (up to 140 ciently. One operator can manage both case inspection/rejection (ensuring that reams/min, kraft and polypropylene wrap- palletisers on a 16-pocket line, thanks to only good quality cases proceed to the ping), Model 124 ream inspector (ensur- a sub-supplier’s fully automated pallet palletiser). The palletiser is identical to ing that only good quality reams proceed labeling solution and Automated Guided those on the 16-pockets lines. High auto- to the case packer), Model 137 stacker Vehicle (AGV) pallet pick-up. AGVs also mation, a moveable touch-screen and accumulator (600 ream capacity allowing deliver the reels to the sheeter. excellent accessibility facilitate operation ■ the line to run even with a downstream While the two 16-pocket cut-size with minimal manpower. stoppage), Model 162 case packer (up to lines focus on output, the flexible 8- The brand new plant allows E.C.H. 30 cases/min), Model 123 case inspector pocket cut-size line combines versatility Will to demonstrate their expertise as (ensuring that only good quality cases and productivity. At 400 m/min, the 8- a turn-key supplier, drawing on experi- proceed to the palletiser). Completing pocket sheeter, sporting five double ence from installations around the world. each line, W+D-Langhammer delivered a unwind stands with zero-speed splicing, “It’s turn-key in that we developed the high-speed, heavy-duty palletiser for up can produce up to 100 reams/min and systems, specifying and adjusting them to seven layers (max 2.3 m high, 1.5 t/pal- all formats between A4 or letter-size to meet requirements optimally, and let), to fill shipping containers more effi- and 30.84 x 45.72 cm. Hole punching is delivered, installed, set-up and readied flexible, too, with four punching units to them for testing,” noted Klaus Aarestrup, meet various market requirements. With managing director. “Yet, it was also a automatic slitter positioning and quick- partner relationship, communicating clo­ change features, the machine is designed sely at every stage. We help with their to minimise format change times. planning, sourcing and relevant technical Discharged reams are directed into matters.” one of two packaging lines, either a bulk The Manufacturing Execution Sys- line for cases with 2,500 loose sheets, or tem (MES) keeps production running a highly flexible Pemco line featuring: smoothly by bridging the gap between sheet inserter (from sub-supplier, inserts the Enterprise Resource Planning system top and bottom promotional sheets used (an ERP called PPMS) and local machine with clear polypropylene wrap), Model controls. 33 ream wrapper (up to 100 reams/ Furthermore, ExpertOnline contains min, kraft and polypropylene wrapping, all relevant operation manuals, pro- semi-automatic size change), Model grams, software, etc., and, when the mill 124 ream inspector (ensuring that only requests, it provides remote access to good quality reams proceed to the case the machines by KPL experts. This allows packer), Model 137 stacker accumulator quick diagnosis of machine disturbances (480 ream capacity, allowing the line to and immediate support, either online run even with a downstream stoppage), or by sending an expert onsite. It’s also The Pemco Model 137 stacker Model 163 case packer (up to 22 cases/ used for training and updating documen- accumulator min, semi-automatic size change) and tation. ■

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ABB Paper machine drive solution for improved productivity ABB’s top knowledge and qua­ lity within the Paper Machine Drive Solution enabled a fast and on-time startup of PM 4 in Setúbal. Both the progress of start-up work and the quality of the equipment were excellent. All the agreed deadlines relat- ing to the start-up, test-runs and production were promptly on schedule.

he cooperation between ABB, “Tthe end customer, consultants and paper machine manufacturer has been smooth and successful. The project proceeded well without any major prob- ABB’s delivery also included installation, supervision and training lems,” says Toni Haapala, project mana­ ger from ABB. “The technical descrip- winder sectional drives, rewinder and Portal Operator Stations, the GOP2010 tions and customer needs were clear and pump drives with 81 ACS800 Multidrive control panels, and for remote connec­ even though some changes came during inverters and motors and process drives tivity to the drive systems. The delivery the project, those were clarified fast and of 324 ACS800 Multidrive and Single- also included installation supervision, efficiently. All parties had the ability and drive inverters. Altogether the mill has training, startup and stand-by services. willingness to stay focused on their goals 405 inverter units for the process motors. ABB’s paper machine drive solution which centred on implementing the most The paper machine, winder and rewinder enables improved productivity by means modern paper mill in Europe.” drive systems also have a test rig for of enhanced data logging, maintenance  ■ ABB’s PMC800 paper machine drive the ACS800 Engineering Demo unit, the tools and expert services, either on site delivery for Setúbal consisted of two PMC800 Dataloggers, the 800xA Process or remotely. ■

Edifer Outpacing civil construction works

Edifer’s participation in the project in Setúbal has consisted of civil construction work on the warehouse, processing and shipment areas as well as in the execution of the pipe rack con- necting the pulp factory to the new paper mill.

he biggest challenge of this project Twas to meet the tight deadline while the execution project was simul- taneously being prepared by Portucel Soporcel. Edifer is familiar with these demanding contracts which imply a con- A demanding task: the civil construction

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struction model requiring high integra- Development, and Environment and vices, facades, exterior cladding solu- tion of precise logistic expertise and Energy. tions and special finishings. The Business workflow, and this project reflects the The business unit Engineering and Development division is aimed at the company’s strong technical capacity to Construction covers all interventions re­ diversification and expansion of Edifer’s undertake projects of such a demanding lated to engineering works, public works activities. It focuses strongly on high nature. and building construction. With notable added-value markets, with a global stra­ Edifer is a privately-owned Portu- experience in all these sectors, it is the tegy of positioning in key areas (health guese business group operating mainly core business of Edifer. The Real Estate and other social facilities, roads and other in the construction industry in the private division represents the company’s direct transport infrastructures) and the creation and public sectors. It is one of the largest investment in the property sector. Edifer of a diversified base of concessions. Portuguese construction groups, with Imobiliária is a benchmark brand asso­ The Group’s Environment and Energy a technical reputation for engineering ciated with high quality and high value unit concentrates its present and future and construction quality. Presently, the products. Industry covers the industrial expertise on this domain which is relevant Group’s subsidiary companies operate and manufacturing operations. Through in terms of diversification, particularly on in five areas: Engineering and Con­ Edimetal, it enjoys market leadership renewable energies and specialised pub- struction, Real Estate, Industry, Business in the provision of corporate image ser­ lic services. ■

TM System Finland Reliable and energy-efficient solution for trim handling

TM System Finland has delivered two separate trademarked Trim- vac trim handling systems to Setúbal: one system for PM 4 ■ and one large-scale system for the converting plant. The converting plant trim handling system also includes a dry trim handling system for start-up and PM shut-down periods, and a dust removal system for the sheeters. In total, a trim handling The Trimvac trim handling system for eleven machines was system in theory delivered.

he converting plant‘s Trimvac system etc. for the trim handling system had to handling system consists of a chopper Tis one of the largest systems of its be carefully designed in order to mini- fan with a booster fan because of the kind ever delivered. Portucel Soporcel mise the pressure loss of the system and long transporting ducting. The chopped already had ten years of experience with thus energy consumption. All dampers trim is collected into a baling station, also the Trimvac system, so it was a natural and special parts of the ducting were delivered by TM Systems. The dry trim and safe choice to choose it for this new therefore developed and designed by handling system uses the same ducting mill, too. TM Systems. as the Trimvac system. The operator can The large number of cut-size and One of the most important features thus freely choose which trim handling folio sheeters in this project require a reli- of the Trimvac system is that it will not system to use. able and energy-efficient solution for trim disturb the sheeter trim cutting. The The trims from the PM 4 calender, handling. Different sheeters have variable tension of the trim can be adjusted to fit and the trims from the rewinder and lab demands for trim handling. The width different production demands. sheeter, are collected into the Trimvac of the trim varies, requiring different In addition to the Trimvac system, separator which is located in the vicinity features for the systems. Due to the size the customer requested a dry trim hand­ of the reel pulper. With this system, trim of the converting plant hall, the longest ling system for the commissioning period handling, even at the maximum speed of distance from the sheeter to the Trimvac of the sheeters and for the periods when the calender, is trouble-free. With a con- separator is more than 150 m. The duct the machine is shut down and the pul­ ventional type of trim handling this may elements, such as t-connections, elbows pers are not in operation. The dry trim not have been the case.

28 Special Edition ipw – November 2009 SupplierS

Nowadays, energy consumption is an by a frequency converter which enables chopper fans, the vacuum fan has no cut- important aspect when considering the energy usage optimisation for different ting knives etc. which require frequent purchase of a trim handling system. The productions. Energy efficiency was one of maintenance. Because of the vacuum in Trimvac system is also highly competitive the key issues in the engineering design. this trim handling system, the environ- energy-wise; in the converting plant, it The energy consumed per transported ment is kept clean, thus minimising the only uses one third of the energy of a trim flow is the lowest ever built by TM cleaning costs. The Trimvac system has conventional dry trim handling system or Systems. already been installed in more than 700 a high vacuum trim handling system. The The Trimvac trim handling system paper mills. ■ vacuum inside the separator is controlled only has one vacuum fan. Unlike the

MAN Turbo TURBAIR vacuum systems for extreme flexibility and adaptability

Portucel Soporcel selected trademarked TURBAIR for the vacuum system for the new PM 4. The ecological and eco- nomical advantages were strong factors in the final decision.

he TURBAIR vacuum system consists Tof two multi-stage blowers type RC 118-4 for the forming and press section of the paper machine and one single- stage blower type RT 71-1 exclusively for the felt conditioning. Vacuum ducts, water separators with extraction pumps, exhaust air silencing and the plant control Turbair vacuum blower  ■ technology were all designed in close co-operation with Pöyry and the project energy saving with exhaust air heat More than 1,000 TURBAIR blowers are team of Portucel Soporcel. recuperation, low electrical drive power currently in operation worldwide. Some of In addition, a comprehensive train- consumption, no sealing water required, the most recent references are: Holmen ing programme for the mill’s operation constant vacuum on all PM suction Paper Peninsular PM 62 in Spain, Palm and maintenance personnel took place points, independent of the fine paper Paper Lynn PM 7 in the UK, Myllykoski during the commissioning and optimisa- basis weight, high reliability thanks to a Plattling PM 11 in Germany and Oji Nan- tion phase of the PM 4. Main advantages robust and proven design as well as less tong PM 1 in China. ■ of the Turbair vacuum system include space requirement for the equipment.

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Special Edition ipw – November 2009 29 SupplierS

GAW Sophisticated starch preparation

or the third time already, Portucel FSoporcel is relying on the quality, adherence to schedules and the flexibility of GAW, and has awarded the supp­ lier the order for the starch preparation plant, as well as the preparation plant for paper and cleaning chemicals and the working stations for the provision of the new paper machine. The order has a value of EUR several million. The scope of supply includes the entire mechanical planning, parts of the electrical planning, the delivery of plant components like tanks, pumps, agitators, manual fittings, all piping material, and supervision during the assembly phase, start-up and training on site. Due to the variety of chemicals that are processed in the new paper machine, the complexity of the preparation plant

for chemicals should be mentioned. It Tanks of stainless steel and fibre-glass reinforced plastics in sizes of 15 to 50 m3 comprises a filling station for fluid or dry ■ products, storage tanks, powder silos, of chemicals as needed. As the chemi- All the parts of the plant arrived on site preparation plants for diverse starch cals in use are extremely different, the last December, and the installation took powders, and blending stations as well utmost importance has to be attached to place from February until July. The plant as emulsifying plants for the production the handling and neatness of the plant. was started up successfully in August. ■

Raumaster Paper Setting new standards in core cutting

aumaster Paper has successfully Rstarted up a comprehensive core handling line at the new mill in Setúbal. The total delivery from the Finnish supp­ lier consists of several subsystems: a robot picks up parent cores from stor- age and transfers them to the CleanCut core cutter. Cut cores are automatically transferred up to two winders by a line consisting of about 100 m of conveyors and several core lifts. The recycling line transfers the butt rolls from the sheeters to the stripper and, after inspection, the stripped cores are passed on through sorting and a buffer storage back to the main stream. It consists of two core robots, several lifts, multi-floor storages and conveyors. The pulper is fed by two lines. Butt roll unwinding line consists of a stripper and a wide belt conveyor. Broke roll splitter The core cutter

30 Special Edition ipw – November 2009 SupplierS

features a traversing cutter enabling a steady material flow into concept integrates parent reel handling, winding, core hand­ the pulper. The heart of the delivered system is the patented ling, roll handling and wrapping, broke handling, warehousing, CleanCut process, which paves the way for new standards in sheeter operations, vehicle loading and related automation into core cutting. Cleanliness, cut surface quality and cutting accu- a complete single supplier delivery. The main target of the new racy meet even the most stringent requirements. concept is to improve the productivity of the paper finishing Raumaster Paper’s process know-how extends over the and converting processes. The supplier provided all products entire paper handling technology and logistics in paper mills, and services from the efficient system layout engineering to converters and printing houses. The FINMaster roll finishing skilled site supervision and training. ■

Mota Engil Execution of piles, earthworks, paving and buried infrastructure

Mota Engil was responsible for the foundations of consolidation for operating this machine. This method con- of the new paper mill, composed of piles of vari- sisted of riveting the metallic coating to the piles concreted in able diameters from 400 to 1000 mm in a total situ. The piles or the metallic coating were riveted exactly in the position referred to in the detailed drawings, with the necessary amount of 98,000 m. Two systems were used dimensions and depths, by pile-driver. The order also included when building the piles: moulded piles and piles earthworks and street paving around the mill, as well as the riveted in concrete. buried networks: water, electricity, sewage and rainwater. ■

he moulded piles consist of piles in diameters of 400, 500, T600, 800 and 1000 mm. Piles foundation in situ refers to foun- dation composed of piles made of reinforced concrete, whose execution starts by drilling, then reinforcing and concreting, Automated warehouse trucks with inclusion of pipes in the ground in order to ensure the soil’s Visit us at LogiMAT- containment and thus the drilling stability, or drilling by using in Stuttgart,expo thixotropic sludge Hall 7 / Stand 410  ■ ∙ fast delivery and short payback time March 2nd to 4th 2010. or not. ∙ very long life cycle up to 20 years Riveted piles Quantities ∙ modular solution that can be tailored to customer needs in concrete of ∙ minimized injuries and no damaged goods 457 mm diameter Buried Piles: 98,000 m were used for the Earthworks: 150,000 m3 foundation of the Structural Steel: 3,200 t paper machine’s Asphaltic Concrete: 10,000 t main body in Pipes for buried order to obtain infrastructure: 18,000 m the highest levels For over 60 years Rocla has been the way-maker in intelligent material handling solutions. First AGV instal- lations took place in 1983, and since then Rocla has delivered and installed almost 8000 automated guided vehicles in more than 1000 applications worldwide.

For more information Tel.: +358 - 20 - 778 1228 www.rocla.com

The intelligent way to move

A look on the construction when the piling was done in May 2008

Special Edition ipw – November 2009 31 SupplierS

Brunnschweiler Aerothermic installation and ventilation system Once again, Portucel Soporcel has put its trust in Brunnsch- weiler for the supply of the aero- thermic installation and the ven- tilation system. The collaboration dates from 1991 and, at the turn of the year 2007/2008, the company received its third order from the Group, for the supply and installation of the hood and ventilation turn-key system, the hall ventilation system and the HVAC installation for the project

in Setúbal. Outstanding hood from Brunnschweiler he Brunnschweiler hood stands out Tbecause of its easy dismantling fea- Furthermore, a new roof type has and water/exhaust heat exchangers pro- ture, which allows quick access to the been supplied, which improves the ther- vided with an automatic washing system drying section to carry out any neces- mal insulation, the air tightness and the with stainless steel piping. sary maintenance work, without losing plenum formed by the roof section to The complete Optiformer exhaust ■ the required performance of a closed allow better suction of the exhaust. The system was supplied in stainless steel AISI hood which allows inside dew points up closure between the lifting doors and the 316L and the drop separators were manu­ to 64.7 C. Roof and panels can be easily aluminium half-height beams has been factured in the Brunnschweiler work- and quickly dismantled and this helps upgraded with a double closure made of shop at Munguia. The complete pulpers the maintenance personnel in their job. rubber and special felt. The lateral panels exhaust system was supplied using nine Moreover, in this project, materials from of the hood have been designed with a different pulper exhaust groups. These a new generation have been supplied special brake of thermal bridge to reduce exhaust and blowing fans were manufac- without changing the overall philosophy. the heat leakages to a minimum. tured by Baltogar, part of the Brunnsch- The new machine has an evaporation of Five exhaust groups of about 775,000 weiler Group. The company also supplied

80,604 kgH2O/h at the pre-drying section kg/h total exhaust flow and another five the ventilation system, including HVAC and 18,720 kgH2O/h at the after-drying blowing groups of 570,000 kg/h total equipment, for the additive plant, refiner section and is totally enclosed by a hood blowing air have been installed in the room, vacuum blowers room, PM 4 hall, with the following dimensions: mezzanine floor. Steam and condensate core handling, roll grinding room and heating coils of galvanised steel have roll storage, folio sheeters and cut-size Pre-drying after-drying been made with a special separation sheeters hall, process reel store and car- length m 88 24 between fins in order to allow a better ton and copier reel store as well as HVAC cleaning operation and to avoid the accu- equipment for diverse electrical rooms. width m 16.2 16.2 mulation of dirt. The exhaust flow passes Installation, commissioning and start-up height m 7.9 7.9 through five stainless steel air/exhaust were done by the company’s personnel. ■ Moventas Santasalo Drive solutions with minimum vibration and noise

Moventas Santasalo’s application-based drive solutions are oventas is one of the leading integrated parts of the new paper machine. The drive solutions Mexperts in mechanical power trans- mission globally. Moventas Santasalo, have been designed for absolute reliability at the highest machine a subsidiary of Moventas, provides speeds, and special attention has been paid to minimising vibration the pulp and paper industry with drive and noise levels. solutions and life-cycle service support

32 Special Edition ipw – November 2009 SupplierS

labelled with the Santasalo trademark. The company’s products and services are built on decades of experience and cutting-edge technology developed by Metso Drives, Santasalo, Valmet and Sau- erwald. Moventas Santasalo is the origi- nal equipment manufacturer for all these high-quality brand names in mechanical power transmission. The company’s turn- key delivery of mechanical drive solutions for the Setúbal project comprised the complete mechanical drive solution pack- ages (sym rolls in the press and calender sections and suction rolls in the forming and press sections) including all the requi- Completion of the drying section for which Moventas Santasalo developed special drives site accessories. Moventas Santasalo also developed special dryer section drives pact centre drive unit for the unwinding optimisation of mechanical power trans- according to the DRG concept for fast stand of a winder integrates the func- mission equipment in the paper manufac- paper machines. The DRG dryer section tions required for continuous operation turing process. drive is compact in design and includes of the automated winding process in a As the only supplier of mechanical all necessary components built into the single pre-tested unit. A hydraulically power transmission, Moventas Santasalo housing of the gear unit. The unique operated reel spool coupling engaging is able to provide the entire layout engi- internal coupling design of the DRG drive mechanism and integrated disc brakes neering. The company also designs and permits higher machine speeds, regard- for emergency stop ensure safe and reli- supplies complete and comprehensive less of misalignment resulting from ther- able control of the process. Furthermore, modular gear series which meet specific mal expansions, mounting inaccuracies or the company has delivered trademarked customer application requirements. The distortions in the machine base. Santasalo modular drive units for sec- customer can rely on one supplier for a The supplier’s solutions for reeling tional drives in the paper machine and turnkey delivery from a motor shaft to a ensure controlled web tension through- the winder. The order also included a driven machine shaft and get a custom- out the reeling process and they run very spare part package and layout engineer- ised drive solution on each drive position. quietly, minimising noise impact. A com- ing to ensure complete adaptability and ■

 ■ MSK Covertech Implementing the future of film shrink packaging

For two complete shrink packaging lines, Portucel Soporcel chose use a specially designed MSK hot-air MSK, one of the leading international producers of film packaging system and are each equipped with two machines. Initial negotiations took place in 2007, when, together with gas supply regulators with which the longitudinal and transverse sides can be Carlos Lopes (project manager for stores and processing), the project controlled independently without having team of French and German MSK subsidiaries visited different refer- to mechanically adjust the heating ele- ence plants. There, the high performance and reliability of the MSK ments. The pallet shrink frame adapts equipment, as well as the film roll availability and the enormous perfectly to the different formats in a fully automatic way. Compared to pallet shrink power savings of the pallet shrink frame compared to pallet shrink ovens, this leads to significant energy Moventas Santasalo ovens, convinced the Portuguese project manager. savings with high safety standards. “In the paper, print and cardboard industry, the Drive solutions with minimum vibration and noise y the end of February, 2008, MSK 120 pallets per h. By adjusting the film pallet shrink frame technology replaces Bfinally received the order. After suc- rolls horizontally, the devices are able to the shrink ovens and presents the future cessful completion of the Factory Accept- increase the rolls’ exchange ranges by a of film shrink packaging. This is why ance Test at the beginning of the year, factor and thus simplify the operation. In major international paper manufacturers the machines were delivered this March: combination with MSK’s powerful pallet like Portucel Soporcel have deliberately two film wrap machines, of the type shrink frame technique, energy and film decided to go for MSK, the pioneer of MSK Flowtech, process different prod- consumption are reduced to a minimum. shrink frame technique”, explained Rolf uct dimensions with a capacity of up to MSK Synchrotech pallet shrink frames Vehreschild, key account manager. Apart

Special Edition ipw – November 2009 33 SupplierS

from the shrink packaging lines, the supp­ lier furthermore delivered the conveyor technique and additional modules, such as cover board feeders and robot-label- ling, as well as carry-off logistics. This project is another important refe­ rence for MSK in the international paper industry and it shows once again that the company meets the high demands for energy cost savings, packaging quality, flexibility and packaging performance with their latest state-of-the-art solutions. In the past, numerous renowned paper manufacturers have already been con- vinced by MSK’s high technical standards and have opted for replacement of their shrink oven techniques with pallet shrink frames. Some of these paper producers are Amcor, APP, Arjo Wiggings, Chemning MSK systems package paper parcels and loose sheets, paper rolls, cardboard and print Paper, International Paper, Mondi, Nord- products on pallets while creating a perfect display effect at the same time landpapier, Tullis Russel and UPM. The MSK Covertech-Group belongs shrink and stretch packaging systems being their own one-stop products. MSK to the leading companies in the packag- for pallet loading units, the supplier also sets great store by the high availability ing machines industry all over the world. offers pallet conveyor techniques and and safety of their machines and is well- Apart from semi- and fully-automatic on-plant handling systems – all of these known for its customised innovations. ■

■ Rocla Unique automated warehouse truck concept

ast year, Rocla received an order to nen, director of Rocla’s Solution Business. Lsupply an automated warehouse truck “And because the vehicles are based on solution for the mill project in Setúbal. standard warehouse truck technology, The deal, worth more than EUR two mil- our customers are able to utilise Rocla‘s lion, represents the supplier’s single big- international service network,” he went gest deal of automated warehouse trucks on. so far. It covers around twenty vehicles After an intensive planning and manu­ for transporting reels from production to facturing phase in Rocla’s warehouse sheet cutting and for transporting pallets truck factory in Finland, the vehicles were from sheet cutting to wrapping, with an shipped to the new paper mill in May option for twelve additional vehicles. The and June this year. During the summer, system also includes an automated bat- the reel logistics in the new converting tery exchange station. plant were commissioned and interfaces “After evaluating many AGV supp­ to the mill’s control systems and differ- liers, we chose Rocla because of their ent machine lines were established as advanced technological solution and the planned. best total package”, explained Carlos When production in the new paper Lopes, project manager for stores and mill was just about to hit the heights, processing. completely automated reel logistics, The vehicles are based on Rocla’s equipped with the latest generation unique automated warehouse truck con- of Rocla AWTs and automatic battery cept, which was launched in 2007. “The exchange systems, were fine-tuned and system’s modularity allows us to offer the made ready to automate production in same platform for both pallet and reel the converting area. ■ Automated warehouse handling”, emphasised Anselmi Immo- trucks in action

34 Special Edition ipw – November 2009 TAKE Request detailed information and a trial copy by A FURTHER Telephone: +49 (0) 61 04/606-210 Fax: +49 (0) 61 04/606-333 STEP TOWARDS Email: [email protected]

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 Special issue ipw – November 2009