The Magazine for the Fiber Industry

The Magazine for the fiber industry

01.2017 | siemens.com/magazine/fiber

Fiber industry is in motion

In focus International projects #sipaper Challenges for the fiber industry Solutions for flexible and in the digital transformation efficient production worldwide »It’s about more than the production of cellulose and paper, it’s about sustainable mass production of a wide range of products made from wood as a natural material in the age of digitalization, while challenges and opportunities transform our industry.«

2 siemens.com/magazine/fiber | 01.2017 There is another way AnnetteKradisch

Each year, vast quantities of plastic waste – up to 13 million tons – end up in the world’s oceans, are broken down much too slowly there, and thus enter the food chain. Each year, mankind also releases about 35 billion tons of carbon dioxide – a greenhouse gas resulting largely from burning fossil fuels. The fiber industry is contributing to ecological improvement by gradually converting to sustainable packaging, using renewable sources of energy and biomass materials for chemicals, as well achieving higher recycling rates.

The age of digitalization not only enables new and significantly more variable production processes, some of which are autonomous, it also makes complex simulations and remote maintenance services possible. However, the need for certain products is also changing, and doing so at a rapid pace. In many places this is causing a shift away from graphic paper production to meeting rising demand for packaging and hygiene papers, as most recently happened at Metsä Husum in Sweden, ProGest Mantova in Italy, or Leipa Schwedt in Germany, often under new ownership.

Once again, we are seeing significant investments in new systems for viscose, market pulp, and packaging paper production, especially in Asia. More and more companies are pursuing innovative approaches which use wood as a raw material for creating more than just pulp, paper, or electrical power, but also supply these products to other industries, such as the food and textile sectors.

It is clear that the 10,000 paper and pulp mills in existence throughout the world today will undergo continuous change under these conditions. With many years of industry expertise combined with our products, solutions, and services, we help our customers make their production more environmentally friendly, resource-efficient, and profitable – with integrated engineering solutions, energy generation and distribution, efficient drives, factory-wide process automation, data analysis, and initial cloud services.

In this issue of “The Magazine for the fiber industry,” we will provide you with insights into international develop ments in our industry: How are new market requirements successfully dealt with? How are large projects managed so that they are sustainable? And how do researchers open up new fields of application for a wide variety of products made from the natural material wood?

Join us on a brief journey through a fiber industry in the midst of transformation. I hope you enjoy reading this issue.

Jan Kabus Vice President Fiber Industry Siemens AG

01.2017 | siemens.com/magazine/fiber 3 In China, Stora Enso implements the entire value chain Mikael Leksell, CEO of Process Solutions, Siemens AG, 20 at a single site: from a eucalyptus plantation to production 11 talks about the innovative Swedish fiber industry GettyImages / HuoGuangLiang AnnetteKradisch

Greenpac Mill in North America Making of: Bettina Raunecker and André Vieira Auer is a paper mill with the highest degree 28 build a model to illustrate fiber industry processes 32 of automation Publicis PixelparkPublicis Curtis Schick/Synaptic Digital

4 siemens.com/magazine/fiber | 01.2017 Contents

03 Editorial | 16 News | 17 Imprint

In focus Country references 06 From stalk to smart packaging 10 Made in Sweden The fiber industry is changing Sweden: innovative, business-friendly, 11 First movers and an important base for the fiber industry Interview with Mikael Leksell, 20 From forest wood to cardboard CEO of Process Solutions, Siemens AG, China: Stora Enso implements the entire value chain on the innovative Swedish fiber industry at a single site 32 The intelligent paper mill US: Greenpac Mill is a paper mill with the highest degree Trends of automation in all of North America 14 Paperless in everyday life – utopia or reality? 35 New technology for fast corrugation Paper plays a major role in our everyday lives. Canada: a complete Integrated Drive Systems solution for What are the alternatives? Lake Utopia Paper's production of corrugated cardboard 18 A sheet with many sides 36 Churning out paper Myths surrounding paper making: a look at the facts Germany: Sipaper portfolio for a corrugated cardboard base paper machine at Schoellershammer GmbH 26 Paper architects Interview with Robert Götzinger, Darmstadt Technical 38 Bright prospects University, on the BAMP! project – building with paper Austria: Laakirchen Papier AG on the way to becoming a digital enterprise in the new growth market 28 A perfect loop The future role of the fiber industry in a planned bioeconomy Industrial software 30 The new side of lignin 24 Optimizing processes more quickly Interview with Mikael Hannus, Group R&D Innovation The cloud-based Control Performance Analytics service at Stora Enso, on the company's research into lignin increases the efficiency of industrial processes

Read these and further stories online: siemens.com/magazine/fiber

Cover photo: The digital transformation continues to advance: the fiber industry is embracing change and trends in order to remain competitive in international markets.

(iStockphoto/RonTech2000)

01.2017 | siemens.com/magazine/fiber 5 In focus gettyimages/Silvia Jansen

siemens.com/magazine/fiber | 01.2017 In focus

From stalk to smart packaging

Paper from tomato plants, cosmetics made of eucalyptus or fiber-based insulating materials – the fiber industry is changing. With Industrie 4.0, the next (r)evolution is in full swing. Whether production processes, business segments, or entire markets, digitalization calls everything into question – and offers many opportunities.

ew technologies, new product ideas, more For companies this means remaining viable by N demanding customers – to remain viable, responding ﬂexibly to the ever-changing market companies need a shift in mindset. In the and optimizing processes as far as possible. However, Industrie 4.0 and digitalization era, the formula this makes production more and more complex. In for success is to have customized products of the addition, companies are subject to regulatory require-

highest quality which are immediately available at ments for reducing CO2 emissions as well as for forest good prices. Consumers have also long since come protection and conservation. Growing environmental to appreciate these advantages. But while other awareness on the part of consumers who prefer eco- industry sectors such as IT or automotive have long friendly products over other goods is also an important become involved in digitalization, the digital trans- factor. Efficient production requires not only digi- formation of the fiber industry is only just beginning. talized processes but also recycling and alternative sources of raw material. Thus, it is imperative to con- An industry undergoing change sider the product lifecycle as a whole: fibers are opti- And this change is unfolding although the industry mally used and reused until recycling is no longer is booming. According to CEPI, last year some possible. For example, residues and by-products are 410 million tons of paper were produced worldwide, further utilized – for instance thermally – in order to 91 million tons of which was made in Europe – an generate energy. unprecedented volume. Demand for traditional, fiber- New technologies are also making it possible to obtain based products such as books, graphical papers, mag- cellulose not only from wood but also from numerous azines, and daily newspapers is currently in decline, other plants or grasses such as banana peels or euca- but demand for tissue products such as diapers, paper lyptus – all of which are fast-growing and natural raw towels, and toilet paper is at an unprecedented level. materials. It is also the case that former waste products, In addition, the demand for packaging paper and including plant parts such as tomato stalks, nutshells, cardboard packaging is increasing due to the growing textile waste, or leather residues, can be utilized in importance of the online retail trade. various ways – such as in new, special paper grades.

01.2017 | siemens.com/magazine/fiber In focus

Siemens technologies

Simatic PCS 7 as the basis for the Sipaper APL family. The integrated software solution for model-based process 01 management and control is tailor-made for the fiber industry, increasing quality, profitability, and environmental compa- tibility in production.

The Comos database platform makes an 02 “integrated engineering to integrated operations” concept possible across the entire value chain.

The Simit simulation software forms the link between the Comos database platform and the Sipaper DCS (Distributed 03 Control System) APL. Processes can be simulated in advance and Simit can be used in training. This makes it possible to con tinuously optimize processes and accelerate commissioning.

With the XHQ operations intelligence software, data in different modes can be collected, processed, and displayed in real time. This makes efficient resource management and 04 informed decisions based on up-to-date information possible while ensuring transparency for increased plant performance.

Designed as an open OS for the Internet of Things, MindSphere allows plant operators to connect their machines to the digital 05 world. All system component data can be used and processed in Intelligent evaluation of the MindApp while seamlessly integrating apps and services. process and control data at any time – with the new Sipaper Drive Performance Analytics app

This opens up completely new business areas, extracting substances from eucalyptus for use in especially in cooperation with other industry sectors. cosmetics. In addition, there are numerous other For example, the construction industry is relying products such as biofuels, bike helmets, as well as on environmentally-friendly filling and insulating body panels for cars, aircrafts, or railway car interiors. materials made of pulp or fibers. Composite materials making use of fibers or paper materials are also Fully tapping into the potential becoming increasingly important in building con- The key to a future-proof fiber industry lies in these struction. Mixed with aluminum or plastic, the and other new business segments. This requires digi- building material exhibits the advantages of all the talization of the processes as well as networking of the materials used: while the renewable fibers have good entire value chain, from the supplier to production, all insulating properties, aluminum ensures greater the way to service and the consumer. There are many stability. The chemical industry is also increasingly advantages related to this. This is because comprehen- relying on eco-friendly raw materials – such as sive analysis of the data collected and processed in

siemens.com/magazine/fiber | 01.2017 In focus

this way enables optimization of processes on an lessly combined within the entire value chain and ongoing basis and conservation of resources, making processes to be further digitalized. The competitive- production more efficient and ultimately saving ness of plants can be sustainably increased, and money. This is the only way to enable companies to processes are continuously undergoing further respond flexibly to the changing demands of the optimization. Designed as an open operating system market and consumers – thus fully realizing the for the Internet of Things, MindSphere enables cus- potential of Industrie 4.0. tomers to analyze recorded data securely and effi- To make this possible, Siemens is supporting the ciently. The Sipaper Drives APL solution also continu- fiber industry with its comprehensive Sipaper port- ously analyzes the most important data and makes it folio. It is integrating software and hardware solu- accessible to the operator. In this way companies that tions ranging from integrated drive systems via are only at the beginning of digitalization can take Comos and Simit to the Simatic PCS 7 automation a decisive step toward successful implementation of software, allowing tools and software to be seam- Industrie 4.0.

Signiﬁcant gains for Industrie .

Minimal wastage through the monitoring of the value chain in real Enhanced time. Highly communication customizable with the consumer manufacturing, base. on demand. Significantly increased efficiency in energy con sumption and the use of materials.

Reduced error rates and Reduced CO2 maintenance costs due to emissions due to the the continuous monitoring increased energy, material, of asset performance. and logistics efficiency. Increased pro duction efficiency Maximized through the control logistical efficiency based of plant operations on efficient dovetailing and distribution of the process steps in the processes. value chain.

01.2017 | siemens.com/magazine/fiber Country references: Sweden

Made in Siemens in Sweden

◾ Construction of the first telegraph lines in Sweden (Stockholm-Gothenburg, Sweden Stockholm-Malmö)

◾ Since founding Tekniska Byrå in 1893, Siemens has been active in Sweden for 124 years As Northern Europe’s largest ◾ Company becomes a stock corporation economy and an important base for in 1898 and is renamed Svenska Aktie bolaget Siemens & Halske doing business, Sweden is considered ◾ In 2003 Siemens acquires steam and by companies to be innovative and gas turbine power plants in Finspång, which later becomes Siemens Industrial business-friendly. Turbomachinery AB

◾ Today: 4,200 employees at approximately 40 sites ince the second half of the 19th century, the S Kingdom of Sweden has evolved from an agri- cultural country into a modern industrial society. It is now seen as the most significant economy in Northern Europe. It has a variety of robust industries with a high demand for equipment, machinery, and other technical products. It also stands out for its high degree of innovation and new technologies, and is valued by creative and technology-oriented customers and consumers as well as companies operating globally, including a relatively high percentage of large corporations. In 2006, the Swedish govern- ment announced plans for the complete changeover to renewable energies by 2020 in order to end its dependency on fossil raw materials and nuclear power. In addition to important technical core industries such as the metal and electrical industry, mechanical engineering, the automotive industry, electrical engineering, the IT sector, the energy industry, and med- ical technology, the chemical and fiber industries are also significant in the overall Swedish economy. With 67.1% forest cover, Sweden is ranked 16th worldwide in terms of forested landmass. As a result, wood and paper industries account for more than 13% of the country’s industrial value chain. In the overall assessment of the World Economic Forum’s Global Competi- tiveness Report 2016–2017, Sweden is ranked 6th out of 138 as an attractive investment location. According to a recent study by the International Institute for Management Development (IMD), Sweden is ranked second for its digital competitiveness index (Germany is ranked 17th).

Paper industry locations in Sweden

siemens.com/magazine/fiber | 01.2017 Country special SwedenIn focus AnnetteKradisch First movers

Despite facing the challenges of market disruptions and global competition, the Swedish fiber industry remains one of the powerhouses of innovation, says Mikael Leksell, CEO of Process Solutions at Siemens AG.

Mr. Leksell, Sweden is home to fiber companies have a mindset Internet. At the same time, the some of the biggest and most that is progressive and innovative market for paper board, food and renowned global fiber compa- and they have the skills to act on beverage packaging, and fiber- nies. What makes Sweden so well this approach – which is why they based hygiene products grew enor- suited to fiber production? have weathered the changes in the mously due to changing consumer Mikael Leksell: What makes market so well. behavior, especially in Asia. Com- Sweden so unique is not only an panies had to rethink their business abundance of raw materials and What changes are we talking models and rebuild their paper resources, but also an excellent about? mills – and all within a very short infrastructure in terms of trans- Leksell: Paper mills were among time. The Swedish fiber industry port, electrification, and communi- the first industries to feel the was among the first to act on this cation. On top of that is a highly impact of digitalization – their change with both machine builders skilled workforce with vast exper- newsprint business saw a massive and fiber companies using ad- tise in the fiber business: Swedish decline with the advent of the vanced technology to increase

03.201701.2017 | siemens.com/magazin | siemens.com/magazine/fiber/industry RubrikIn focus

Mikael Leksell Per Mikael Gustaf Leksell has been CEO of the Process Solutions Business Unit at Siemens AG since 2016. From 2010 to 2014, he was responsible for fiber industry applications at Siemens. From 1997 to 2010, he worked in various capa- cities in Sweden, including positions as project and sales engineer, industry service manager, and country division manager industry solutions. Leksell completed his studies in mechanical engineering at the Royal Institute of Technology in Stockholm, Sweden. AnnetteKradisch

siemens.com/magazinsiemens.com/magazine/fiber/industry | 01.2017 | 03.2017 Country special SwedenIn focus

“ And now we are talking about the next challenges: how to securely and productively bring the assets in the ﬁber industry to the Industrial Internet of Things.”

Mikael Leksell, CEO of Process Solutions, Siemens AG

flexi bility and efficiency and to opti- nies and we offer wide-ranging change in its operations, but we mize their manufacturing processes industry expertise in automation need to be able to prove the bene- in order to remain compe titive. and electrification. We can support fits. And this is where we can again the fiber industry with tools for use our broader industry and tech- What does the new fiber business the remote monitoring of opera- nology expertise. It is not just about look like? tions, optimization of lifecycle and having the right tools and products Leksell: The market has become a asset performance through digital but rather about being able to sup- lot more global and diverse. This is plant models, and for streamlining port the fiber industry's goals in especially true in the food and bev- design and engineering processes – terms of time to market, quality, erage industry where fiber products and we have an equally strong safety, availability, and reliability. are tailored not just to enable con- footprint in the physical world with When we introduce new technolo- venient handling, but also to offer a large installed base and a broad gies, we need to be able to show the a substitute for traditional packag- portfolio of products for automation value they can offer in these key ing – for example, to replace plastic and electrification, as well as a areas. And together with the fiber wrapping. Cellulose-based packag- global network of fiber industry industry, we have already achieved ing not only comes from a renew- experts. So we are in an excellent a lot. I started my career in the able resource, but it can also be position to offer solutions that will fiber business at seventeen, work- modified to help preserve food bet- help the fiber industry exploit the ing as a nightshift operator during ter, thus addressing both the issue opportunities of digitalization my studies in what was then a of sustainability and food safety. while securing investments and largely analog plant with local Fiber products provide a more offering real value. We work closely control. Today, you can monitor sustainable source for the textile with the leading OEMs in the fiber and support the operations of a industry when replacing cotton, industry both in Sweden and across paper mill in China from a central which is often grown in competition the globe to integrate equipment control room in, say, Stockholm – with food crops. And last but not design and electrical and auto- the changes have been extra- least, trees can also be a source for mation systems in order to create ordinary. And now we are talking a whole range of new products – an optimal solution for each appli- about the next challenges: how to from biofuels to green chemicals. cation – and this value-driven securely and productively bring the Scandinavia and the Swedish fiber approach is highly appreciated by assets in the fiber industry to the industry in particular are driving the industry. We have won several Industrial Internet of Things, how forward these new applications and large projects in Sweden because to provide smart tools for decision using automation technology and we were able to demonstrate that support and process improvement digital tools to upgrade their plants our solution makes the biggest strategies – and how to ensure that and businesses accordingly. contribution to the lifecycle value the intellectual property of our of the plant. customers and partners remains What opportunities do you think secure in an increasingly open and this provides for Siemens? Will the market changes also collaborative world. And again, Leksell: I believe that we can offer impact your fiber business? Sweden is in a good position thanks a lot of tools to benefit the fiber Leksell: Definitely. The Swedish to its skilled workforce and strong industry: we are one of the largest fiber industry is ready and willing IT industry. I am excited to see what global industrial software compa - to adopt innovation and promote the future will bring.

03.201701.2017 | siemens.com/magazin | siemens.com/magazine/fiber/industry Trends Paperless in everyday life – utopia or reality?

Paper plays a part in our lives in the most diverse ways in almost everything we do. People try Hygiene again and again to make day-to-day life paperless, Papers but is a life completely without paper really possible? And what would it look like? Sanitary and Household

s er p Uncoated Woodfree Pa s g r n Graphic paper e ti p ri Coated Woodfree a W Whether at work or at home, leading our P & daily lives without any magazines, print- ic g in outs, notepads, and address books on our h t p in Coated Mechanical desks would probably be unthinkable for r a P many. Some companies have already tried r G to convert their workplaces to purely digital ones – but it was never possible to put this idea into practice permanently. For example, there are still concerns that digital Uncoated Mechanical documents have no legal validity or are not adequately protected against unauthorized third-party access. At the end of March, a regulation was passed which ensures that electronic documents are legally recog- Newsprint nized throughout the EU. However, no matter the form, location, or time at which we hold graphic paper in our hands, it will still be a while before sensible and practical Paper Production in Europe 2016: alternatives prevail and are accepted in our daily life. 91 million tons

There’s paper here, too:

Living in a cardboard box?

Inspired by a tomato carton, the Dutch company Fiction Factory developed the Wikkelhouse. It is sustainable, recyclable, and designed to last 100 years. To achieve this, wooden cladding was glued to 24 layers of corrugated board, protecting it from environmental effects. Darmstadt Technical University is currently researching buildings made of paper; see p. 26. Yvonne Witte Stefano Tinti

siemens.com/magazine/fiber | 01.2017 Trends

Hygienic paper What would life be like without tissues, paper napkins, paper towels, diapers, or even toilet paper? One person or another might think that it wouldn’t be so difficult, but how often do you habitually reach for a paper towel instead of using a cloth? And what would happen if from one day to the next the production of toilet paper were halted and you had to look for alternatives? Everyday life with cloth handkerchiefs or napkins needing to be washed after each use, or with hand dryers, which also stir up germs and bacteria along with the air, would certainly be quite inconvenient.

P ac ka Packaging paper gi ng Thanks to the rise in online commerce, P the packaging industry has experienced ap e an upswing in recent years. But what rs would happen if there were to be no more a paper packaging for our orders or for n d private parcel delivery? Regardless of B whether it involved books, electrical appli- Case Materials o a ances, clothing, or food, everything would r d arrive either unpackaged or in paperless s packaging. Do you think our purchases would all still be in perfect condition? In addition to shipping boxes, there are many other forms of packaging made out of Carton Board paper, such as moving boxes, paper sandwich wrappers, or paper bags. There will probably not be a paperless alternative Wrappings to paper shipping boxes any time soon. There are several other packaging paper products which would be easier to do without in day-to-day life, for example by simply taking your lunch in a container Other Paper andOther Board Paper for Packagingand Board CEPI/Publicis Pixelpark CEPI/Publicis instead of using sandwich wrappers.

Dining out in a cardboard restaurant Paper in sports and recreation

Furniture made only out of cardboard already Paper airplanes and kites in the exists: lamps, stools, shelves, chairs, tables, sky are a familiar sight. Paper beds, and decorative items. A cardboard boats have also been floating on restaurant was presented at the International various bodies of water over the Home Fair in Milan, and in Shanghai and past few years. They compete in Taiwan there are already the first Carton paper boat regattas – sponsored King restaurants, where virtually everything by the Water Rescue Service on is made from cardboard: even soups are Lake Tegernsee, Germany, for cooked in cardboard woks. example. KJR Miesbach shutterstock

01.2017 | siemens.com/magazine/fiber News

World record technology for everyone

Is there anyone who did not enjoy making paper airplanes as a child? There are countless techniques for folding large or small paper airplanes able to fly two, three or even five meters. And then there’s this one: a paper airplane that flies more than Important data at a glance with the 69 meters! That is seven times the Sipaper Drive Performance Analytics MindApp length of a London double-decker bus or nearly as long as the rotor blade of a wind turbine, and nearly A new benchmark sets a world record. The beauty of it is that everyone can make this super for transparency airplane, and there isn’t much to it at all. All you need is a sheet of A4 paper. A sectional drive is at the core of every paper machine. A high volume of process and control data is used for The instructions are available here: controlling its complex functionality. Both intelligent youtube.com/watch?v=EDiC9iMcWTc and accessible at any time, the new Sipaper Drive Per- formance Analytics MindApp evaluates machine data while creating a new benchmark for transparency in the fiber industry (pulp and paper industry). Energy consumption, productivity, start-up times, web breaks, and operator intervention are analyzed without additional configuration effort or added expense. Clearly structured evaluations ensure transparency and allow the causes of a shutdown to be rapidly detected while The Paper Airplane Guy identifying potential for optimization in the produc- Held in a paper clip, the accuracy of the fold tion process. is checked at the end

Welcome to the world of Sipaper

We are in the midst of a transformation from an analog to a digital economy. This development is also forcing the ﬁber industry to reposition itself. Siemens is supporting this industry with a comprehensive portfolio and long-term partnerships. The demo center in Erlangen, Germany – Sipaper World – shows visitors many different aspects of automation and drive technology – directly on-site or via livestreams, remote access, or as presentations. A big attraction is the fully functional model of a AnnetteKradisch paper machine including a control room. All related Andreas Beck, member of the Siemens AG Sipaper processes “above and beyond the machine” can be development team, demonstrates the fully functional paper machine model controlled and simulated from the control room.

siemens.com/magazine/fiber | 01.2017 News

Imprint

Simply minimize Published by: Siemens AG Communications Wittelsbacherplatz 2 hazards 80333 Munich [email protected]

With its extremely complex processes, drive technology in the fiber Responsible for content: Jan Kabus, Jürgen Mielke, Dr. Hermann Schwarz industry cannot afford to have any vulnerabilities, because any fault e-mail: [email protected] or malfunction can have fatal consequences. The primary objective (in accordance with the German press law) is therefore to use technology to minimize potential hazards to the Winfried Wittmann operator, machine, and the environment, without adversely affecting Concept, coordination: the industrial production process. The comprehensive safety concept Kristin Hussner

Sipaper Safety Integrated reliably eliminates sources of danger and Editorial committee minimizes risks – efficiently and in accordance Jürgen Mielke, Dr. Hermann Schwarz, Kristin Hussner, Jan Kabus with prevailing standards. Sipaper Safety offers Publishing house: the following advantages: Publicis Pixelpark, • Integral component of the Sipaper Drives APL Postfach 32 40, 91050 Erlangen Editorial staff: Dorit Gunia, Eva Gansen, and Sipaper Winder APL drive solutions Dominik Heinz, Sarah Werner, • Velocity monitoring using standard Kerstin Purucker (ext.) components Art direction: Reinhard Sorger Layout: Bettina Raunecker • Convenient selection of operating modes Copy editors: Sabine Zingelmann, Julia Robinson on control panels and WinCC stations DTP: TV Satzstudio, Emskirchen • Entry of new diameters for the safety Print: Wünsch Druck, Ursensollen program via the operating system Circulation: 11,500 (without new commissioning) © 2017 by Siemens Aktiengesellschaft • Integrated diagnostics via the existing Munich and Berlin. operating system All rights reserved.

Siemens AG • No additional hardware required Article number: CGMP-M10034-00-7600

The concept works with signiﬁcantly less Printed in Germany engineering effort and ensures higher availability and system The following products are registered trademarks consistency. All the requirements of EN 1034 are fulﬁlled with of Siemens AG: SIPAPER, MindSphere, COMOS, SIMIT, SIMATIC PCS 7, a patent-pending process. XHQ, CPA, Integrated Drive Systems, WinCC

If there is no special mention of trademarks, trade The brochure is available here: names, technical solutions, or similar items, this siemens.com/sipaper-safety-en does not mean that these items are not protected. The information in this magazine contains only general descriptions and performance features which do not always apply in the described form in the actual application or which may be subject to change in the course of further development of the product. The specific performance features are only binding if they were agreed expressly in the Major contract for Siemens contract. at BillerudKorsnäs Gruvön

Siemens has won the contract from a large Swedish industry customer, BillerudKorsnäs in Gruvön to supply equipment for their “Next Genera- tion” board machine. As of the ﬁrst quarter of 2019, 550,000 tons of board for, among other things, liquid packaging solutions will be produced at the plant. At approximately 600 million euros, it is the largest investment in the history of BillerudKorsnäs. The commission will be jointly executed by Siemens and Voith as the machine supplier. Siemens will be responsible for the engineering, installation, and delivery of medium-voltage process motors and the sectional drive of the Sinamics drive system, and will even supply the Simatic PCS 7 process control system based on Sipaper solutions. The new Sipaper PCS 7 platform at the paper mill lays the foundations for further digitalization solutions such as the Sipaper Drive Performance app, Control Performance Analytics, and other applications that will help increase plant output.

01.2017 | siemens.com/magazine/fiber Trends A sheet with many sides

Whether as a newspaper or book, packaging material, or hygienic utensil, some 1,900 years after its invention, paper continues to be widely used in everyday life and continues to be an indispensable material. Many find fault with paper making – it is said that the process is too elaborate, that it wastes resources, or that it harms the environment. But a sheet always has more than one side – what is behind these common myths about paper?

“The paper industry destroys forests” “We could just recycle and not cut down any more trees”

Europe is already the world champion in recycling: more than half of all paper is recycled, and nine out of ten newspapers are made from recycled paper. However, this process also has its limits. Cellulose fibers can only be processed about four to eight times. When they can no longer be used, they are converted into renewable or green energy. In order to keep the paper cycle alive, fresh fibers must be added again and again. Recycling is not suitable for all types of paper, because the desired characteris tics can sometimes only be achieved with fresh fibers, as can be seen in graphic paper. Moreover, roughly 19% of paper is not really recyclable, since it stops being recycled after being used as toilet paper or cigarette paper or is archived in the form of books and documents. The goal of the European paper industry is therefore to maintain the current recycling rate of 70%.

siemens.com/magazine/fiber | 01.2017 “E-communication “E-communication “Paper production consumes production “Paper 4,239 average households could be supplied with with supplied be could households 4,239 average is better thanis better paper-based” electricity demand in EU countries, cloud services are services cloud EU in countries, demand electricity annual toaverage Compared month. asingle in searches of allGoogle consumption power the from energy of Atotal ignored. be not should activities online to of alot energy takes It produced. paper of the comparison, In recycled. is waste electronic of this smart and computers for one ashort is that –and ered already ranked sixth worldwide, with an expected an expected with worldwide, sixth ranked already phones: approximately ten million tons of electronic of electronic tons million ten approximately phones: entire the assessment, alifecycle For friendly. mentally environ more is of which question tothe answer easy no is There environment. the on have an impact munication produce paper, but the energy consumption from consumption energy paper, the but produce Whether we send an e-mail or a letter, both types of com types aletter,both or an e-mail send we Whether the European paper industry recycles about 70% about recycles industry paper European the waste are generated annually in the EU, but only 2% EU, only the in but annually generated are waste too much energy” increase of 63% 2020. by increase

lifespan of the means of communication must be consid be must of communication means of the lifespan of energy would allow a computer to run continuously for continuously torun acomputer allow would of energy of energy kWh 800 roughly Germany In webs. paper drying annual per-capita demand in the EU countries. This amount amount This EU countries. the in demand per-capita annual needs energy, in particular for operating machines and machines operating for energy, particular in needs Like all industrial production, the paper industry also industry paper the production, allindustrial Like is used to produce 200 kg of paper, which is the average average kg the of is paper, 200 which toproduce used is

- - - -

energy surplus energy is then often sold locally. sold often then is energy surplus up to eight months. Around half of the energy consump energy of the half Around months. toeight up uses waste material from the pulping process to generate togenerate process pulping the from material waste uses tion of European paper mills comes from renewable renewable from comes mills paper of European tion biomass energy used in its own production processes. Any Any processes. production own its in used energy biomass

sources that are carbon neutral. The paper industry industry paper The neutral. carbon are that sources five years, this reduces the the CO reduces this years, five environment has declined considerably. declined has environment of carbon dioxide, thereby keeping keeping thereby dioxide, of carbon dioxide during the production process process production the during dioxide agement, the paper industry is help is industry paper the agement, years. With anticipatory forest man forest anticipatory With years. remains a part of the wood during during wood of the apart remains paper until it is recycled. After only only After recycled. is it until paper print created by the release of carbon of carbon release the by created print further processing – for the life of the life the –for processing further carbon the stored, Once clean. air the wide. Although production has risen risen has production Although wide. in recent years, the impact on the the on impact the years, recent in ing to reduce CO toreduce ing by about 5%, and by 75% after 100 75% by and after 5%, about by synthesis to process millions of tons millions toprocess synthesis paper is a tree, which uses photo uses which atree, is paper “Paper production production “Paper | | 01.2017 tainable origin of every sheet of sheet of every origin tainable The renewable source and sus and source renewable The harms the thing begins in the forest. forest. the in begins thing down to its “roots.” Every “roots.” toits down of environment” Paper as a climate killer? as aclimate In Paper actuality, the environmen the actuality, tally-friendly properties properties tally-friendly siemens.com/magazine/fiber paper go all the way allthe go paper 2 emissions world emissions 2 foot Trends ------ - -

Siemens AG/Publicis Pixelpark Country references: China

From forest wood to cardboard

In Beihai, China, Stora Enso has implemented the entire value chain at a single site, from forestry and pulp production through to finished packaging cardboard. GettyImages / HuoGuangLiang Country references: China

“ This project is a highlight in the cooperation and partnership with Stora Enso.”

Engelbert Schrapp, Corporate Account Manager, Siemens Siemens AG

ulp is primarily made from wood and is the base Energy and drive technology from a single source P material for paper. It is thus a logical step for the Construction of the paper mill began in 2014 and was company to handle the entire value chain, in completed in early 2016. Since then, production has other words, not just paper production but forestry as gradually increased to maximum capacity. Stora Enso well. This vertical integration strategy is being followed wanted to work with a partner with a solid interna- by Stora Enso, the second-largest forestry company in tional presence, especially with an excellent reputa- the world and one of the largest manufacturers of paper tion for electrical equipment and automation tech- and packaging materials. nology. The company was not concerned only about About 50 kilometers outside Beihai, in the southeast sufficient experience in the paper and pulp industry. of the Chinese province of Guangxi, the Finnish-Swedish A decisive factor was also the ability to guarantee conglomerate set up a production mill for special card- long-term provision of technical service and local board on a greenfield site. Prior to this, a forest planta- availability of spare parts. tion was established covering 90,000 hectares including With its Sipaper distributed control system (DCS), 72,000 hectares as a dedicated eucalyptus plantation. Siemens was a particularly suitable choice, especially Two types of special cardboard are produced there because the company already had a solid infrastruc- for the local packaging industry: “liquid packaging ture and presence throughout China. board” for packaging beverages, and other liquids and The order for Siemens also included solutions for folding box board. A decisive factor was that previously proprietary energy generation and mill-wide power as much as 80% of the special cardboard impermeable distribution with the required high-, medium-, and to liquids needed for the Chinese market had to be low-voltage switchgear, as well as grid, power, and imported. This situation changed at the beginning of distribution transformers. The system was supple- 2016, with the mill in Beihai now producing 450,000 mented by an emergency power supply and energy tons of liquid packaging board and other products per monitoring and control systems. In the area of drives, year directly in China. In the final phase, some 1,000 Siemens supplied an integrated system with over jobs will be created here, along with about 30,000 addi- 160 drives, including industry-specific control fea- tional jobs at suppliers and customers in the region. tures. Precisely coordinated low- and medium-voltage It all started with the eucalyptus plantation in 2002. motors, frequency converters, and a solution for Eucalyptus was purposely used because it grows rapidly energy switching and monitoring (ESM) ensure high and is an excellent source of raw material for pulp pro- efficiency and maximum plant availability. duction. The plantation sets a high standard for sustain- For Siemens this mega-project has been much more able paper production. than a traditional customer-supplier relationship.

01.2017 | siemens.com/magazine/fiber , beginning of 2016beginning the since China in directly year per produced board packaging of liquid Country references:China for a single dedicated eucalyptus plantation eucalyptus dedicated asingle for , | | siemens.com/magazine/fiber 01.2017

tons

hectares

Shutterstock / L. Kropotov The plantation sets production. a high standard for sustainable paper paper sustainable be imported be to had previously market Chinese the for needed board packaging of liquid

percent Country references: China

In addition to supplying and installing the elec trical system and process automation, Siemens assumed responsibility for all the necessary drive and engineering solutions. Siemens was the single-source provider of detailed planning, monitoring of the installation, and commissioning of all electrotech- nical systems.

Standardized process automation With its Sipaper Distributed Control System (DCS), years Siemens offers no less than 100 years of industry 100 experience and a portfolio of products and solutions of industry experience in Sipaper speciﬁcally tailored to the pulp and paper industry. At the same time, ever stricter environmental requirements in China are taken into account, along with requirements imposed by global competition. The paper industry in particular has to contend with changing demand due to digitalization: while growth in the e-commerce sector is creating an upswing in demand for cardboard and other packaging materials, the importance of paper is notice- ably diminishing due to more widespread digitalized communication and information. Sipaper offers more than extensive horizontal systems (MES). All process control at the new Stora integration through frequency converters, motors, Enso mill is handled by the Simatic PCS 7 process connectors, and gearboxes from a single source. control system. Achieving seamless vertical integration is also a The automation system controls not only the entire considerable advantage, thanks to completely digital production sequence for pulp and downstream card- automation ranging from ﬁeld devices and the con- board production, it also regulates the steam turbines, troller level all the way to manufacturing execution guaranteeing a reliable energy supply for the production mill. Every function in the entire production complex is controlled from one central control room.

Reliable partnership The Stora Enso Tiger Project “This project is an important milestone for the Fiber Industry Division of Siemens but is also a highlight ◾ Power distribution: power and distribution trans- in the cooperation and partnership with Stora Enso,” formers, DC systems, emergency power supply, says Engelbert Schrapp, corporate account manager SCADA-system, cable trays and routing, Comos, at Siemens, about the outcome. In his view, overall and overall engineering services responsibility for the areas of energy and automation as well as the strong presence of the company in ◾ Process electrification: sectional drives including China were crucial. “Basically there were no problems. Sipaper Drives APL, Sipaper Winder APL, motors, This was the smoothest turnkey project of all time engineering, and services thanks to the close cooperation and long-term com- ◾ Process automation (DCS): totally integrated mitment of Siemens,” says Schrapp. uniform mill-wide automation system, including an optional extended lifecycle concept and the company’s first single control room concept

◾ SST 800 steam turbine generator set for energy supply

◾ Ongoing implementation: control performance analytics (CPA) and remote maintenance (turbine and refiner)

01.2017 | siemens.com/magazine/fiber Industrial software

Optimization of the step response

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Optimizing processes more quickly

If all available production data are captured, a previously unknown level of transparency can be achieved in industrial processes. Ultimately, this also increases availability, efficiency, and productivity. The cloud-based Control Performance Analytics service enables efficient analysis of control accuracy.

ncreasing productivity is a critical driver for investing in reliable control accuracy monitoring and I staying competitive, especially for industries if so, how much to invest. that add a great deal of value such as the pulp and paper industry. Production and process data A key to increased productivity need to be captured, filtered, and structured, allowing In the process industry, the lifecycle of process control intelligent analysis to transform it into specific added loops can be as long as 30 years. Continuous moni- value. toring of control accuracy in ongoing plant operation Well-maintained process control systems support is crucial in order to keep the performance of all pro- analytics of this kind, and with correspondingly cess control loops of a given plant transparent. In this configured process control loops contribute to a lower way specific maintenance, service, and adjustment level of variances, optimal plant utilization, and measures can be planned in detail and implemented greater process operability. Manual or automatic in a focused manner. In addition to established soft- mechanisms can be used comprehensively for moni- ware tools for monitoring control quality which can toring control accuracy. However, depending on be installed locally in a plant, there is also a new cor porate philosophy, pulp and paper companies cloud-based service available: Control Performance have differing perceptions of whether it is worth Analytics (CPA).

siemens.com/magazine/fiber | 01.2017 Industrial software

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There are typically more than 400 process control one. After optimization, control accuracy is continu- loops installed in large paper mills. Various studies ously captured in order to detect deviations in a timely show that on average only 50% of the process control manner. loops are optimized in the process industry, particularly in the pulp and paper industry. Through CPA it Long-term process optimization was possible to establish that 61%–86% of process con- Process data is supplemented by CPA. Automatic trol loops were poorly adjusted. Included in this anal- status detection and a KPI calculation for different ysis were six pulp and paper mills in Sweden, Finland, control states enable the required continuous trans- Germany, and China. parency to be achieved. CPA makes it possible to optimize processes in the long term and support fine Reducing operating costs adjustments in a way that makes sense. On a secure Thus, assuming that about half of process control web portal the results for all levels – from plant loops are not optimally adjusted, or up to 200 pro- manager to machine operator – are made available cess control loops, such a plant would be operating securely over a long period of time. The plant operator extreme ly inefficiently, and this would have a direct does not need to build up any resources or acquire impact on operating costs. specific expertise, and it is also possible to claim this About 30% of all process control loops typically “managed service” as a business expense. This saves run in manual mode, and about 25% are still operated on costs while also creating the basis for decisions using the original parameters from commissioning. based on facts. Each controller requires approximately 10 to 14 expert In the “pay-per-use model,” the operator has a high hours – in total over one and a half person-years – degree of flexibility regarding the number of control- in order to initially identify the appropriate process lers to be analyzed over a certain period of time with control loop, investigate it, and then optimize its what are known as “controller months.” For example, control performance. different controllers can be controlled in different numbers per month over variable time periods. Automatically increasing transparency In fact, small control deviations not only improve CPA eliminates the time-consuming process of the quality of the product but also make it possible manual identification. The automatically calculated to operate closer to production limits. In this way optimization recommendations can be used and thus production tonnage can be increased, energy con- reduce time needed for implementation of these mea- sumption reduced, and savings in raw materials sures alone to only two or four hours. CPA performs achieved. these analyses automatically and prioritizes the process control loops requiring assessment by a control technician. CPA calculates the parameters and recom- mends those requiring optimization. The control technician can then concentrate on the process control loops identified and begin with the most important siemens.com/process-data-analytics

01.2017 | siemens.com/magazine/fiber Evgenia Kanli, TU Darmstadt “Building with –this paper” Technical University in Germany Paper Paper year The researchteamduringconstruction ofademonstratortotest BAMP! We talked about the as of part anew project called a a project with Götzinger, Robert Trends in ical process engineering. process ical in paper fabrication and mecha architects what worksandwhere somethingcanstillbeimproved research associate specializing specializing associate research

| | siemens.com/magazine/fiber this area at the Darmstadt

research is being carried out 01.2017 n- The papers which are produced in the process serve serve process the in produced are which papers The Götzinger: Götzinger: Götzinger: Götzinger: Götzinger: This seems to be a field involving many disciplines. disciplines. many involving afield be to seems This Why are you doing research on the topic of building of building topic the on research doing you are Why What are you working on in your doctoral thesis? doctoral your in on working you are What each participant where the challenges and potentials potentials and challenges the where participant each what develop we loops iterative several In objective. deals that advantage the has Paper of knots. presence the or Götzinger: Robert construction engineers, architects, mechanical engi mechanical architects, engineers, construction What is it about your structures that’s new? new? that’s structures your about it is What or of great great for tempo need agrowing is there that fact the given you can actually touch. actually can you the strength in this direction. Generally speaking, speaking, Generally direction. this in strength the greater the direction, one in oriented are fibers the orientation fiber as such nature, by dictated are things that already exists for established construction mate construction for established exists already that abuilding as paper use correctly and understand them engineers, construction tothen be useful architects, to story structures. However, with this material many many material this with However, structures. story we that object an have we other the on and not, does what in properties of physical range awide modify can we multi constructing even long time, for avery wood adjustment of the fiber orientation in paper. The more more The paper. in orientation fiber of the adjustment in other ways. For example, the fiber orientation could could orientation fiber the For example, ways. other in used be also can technology the However, loads. high as and works what learn can we hand, one the On lie. is neers, paper and then discipline engineers. Each a a rials. material. We are of course just taking the first step here. here. step first the taking just of course We are material. rary structures, it is necessary to ask how natural natural how ask to necessary is it structures, rary Especially material. recyclable alightweight, are and cost manufactured be can functionalized, and selectively chosen be can fibers The advantages: more even offers paper And wood. with manufacture It will take a long time to reach the level of knowledge of knowledge level the reach to along time take It will place on a regular basis while pursuing the same final final same the pursuing while basis aregular on place paper? with products can be handled sustainably. Paper offers offers Paper sustainably. handled be can products be used to control the transport of fluid in paper. in of fluid transport the control to used be How is research done in such an area? area? an such in done research is How fundamentals the exploring about also it’s building, Several buildings made of paper already exist. exist. already of paper made buildings Several targeted way. This means it is theoretically possible possible theoretically is it means way. This targeted

known as our demonstrators. These clearly show clearly These demonstrators. our as known building with paper. For example, the ﬁndings would would ﬁndings the For example, paper. with building use paper to manufacture everything that you can can you that everything manufacture to paper use paper engineers as a tool of the trade and would help help would and trade of the atool as engineers paper

reinforcement for components subject to especially want to place certain fibers in a certain position. position. acertain in fibers certain place to want potential here. with a specific problem, and coordination takes takes coordination and problem, aspecific with

The focus of my doctorate is targeted targeted is of doctorate my focus The Our team includes one or more chemists, chemists, more or one includes team Our It’s not just about building a single asingle building about notIt’s just People have been building with with building been have People - effectively, - - - - Aren’t you afraid that the buildings will burn down down burn will buildings the that afraid you Aren’t You have already said that you are still far from the the from far still are you that said You already have protection against fire. Once we have found, tested, tested, found, have we Once fire. against protection the in house, of the analysis structural the consider with adwelling planning We are challenges. climatic complicated. A further difficulty is designing as many many as designing is difficulty Afurther complicated. Then Götzinger: Götzinger: Götzinger: Götzinger: Götzinger: Götzinger: Götzinger: or that the paper will dissolve in the rain? rain? the in dissolve will paper the that or Offensive for the Development of Scientific and Eco and of Scientific Development for the Offensive What approach do you follow in development? development? in follow you do approach What design also plays an important role. important an plays also design of specific developing are we this, on Based other. each there? are challenges and difficulties other What one occupant that has 40 m² of floor space. At the the At space. m² of floor 40 has that occupant one chem does it that away such in function paper of making components as possible from renewable raw materials. materials. raw renewable from possible as components the In period. for alimited only stand to built are that our meet closely to of papers properties the adapt to through four different seasons with their various various their with seasons different four through to make fire and moisture protection a reality with with areality protection moisture and fire make to to building another more complex demonstrator. demonstrator. complex more another building to second step moisture protection, and in the third third the in and protection, moisture step second it make words other in year, one for least at survive we have defined suitable framework conditions. Our Our conditions. framework suitable defined have we when I talk about the project. However, there are ways ways are there However, project. the about Italk when house will be constructed in Darmstadt, Germany and and Germany Darmstadt, in constructed be will house that so kind, of this abuilding in comfortable feel later should people but not least, Last requirements. construction and design, for simulation, methods with products paper and papers suitable connect and and evaluated the solutions, we will devote ourselves ourselves devote will we solutions, the evaluated and we First steps: three then are There foundation. aconcrete already is there assuming are we moment level my for challenge The soften. immediately or not burn for example materials, of building donation the –through industry from for support hoping also We are Excellence. nomic received € In an ideal scenario, this would allow the building to building the allow would this scenario, ideal an In materials. Where are you putting your initial initial your putting you are Where materials. knowledge we have about established construction construction established about have we knowledge being funded? funded? being be achieved by modifying fibers at the molecular molecular the at fibers modifying by achieved be be completely recycled. Finally, a question about costs. How is the project project the is How costs. about aquestion Finally,

individual components. At the same time, we want want we time, same the At components. individual

colleagues in the chemicals industry is therefore therefore is industry chemicals the in colleagues ﬁrst iterative loop of the demonstrator’s evolution, evolution, demonstrator’s of the loop iterative ﬁrst

or by applying functional layers. functional applying by or icals from renewable raw materials. This could could This materials. raw renewable from icals the framework conditions will become more more become will conditions framework the

4.6 million from LOEWE, the State of Hesse’s State the LOEWE, from million 4.6 Our initial focus is temporary structures structures temporary is focus initial Our We are trying to combine, reformulate, reformulate, combine, to trying We are of think ﬁrst people most what is That The project runs for four years and has has and years for four runs project The . focus? focus? - tation in paper. He is a member of the Darm of the paper. in amember is He tation Götzinger received his BA in Mechanical Engi Mechanical in BA his received Götzinger University in the field of paper fabrication and fabrication paper of field the in University stadt Academic Paper Engineering Association Association Engineering Paper Academic stadt technology. of paper area the in specializing and the Zellcheming association. Zellcheming the and a work research team of the BAMP! project, he is he project, BAMP! of the team research mechanical process engineering under the neering. Since then he has been working as working been has he then Since neering. Technical University, Darmstadt from neering Robert Götzinger Robert in this field and a master’s in Mechanical Engi Mechanical in master’s a and field this in In direction of Professor Samuel Schabel. In the the In Schabel. Samuel of Professor direction research associate at Darmstadt Technical at Darmstadt associate research

2016 he graduated with a master’s degree degree 2016 amaster’s with graduated he ing on targeted adjustment of fiber orien of fiber adjustment targeted on ing | | 01.2017 siemens.com/magazine/fiber Trends - - - -

Tobias Krebs, TU Darmstadt Trends Energy

Raw material wood

Delivery of recycled paper

Delivery of wood

A perfect loop

Six years ago, the EU commission launched “A Roadmap for Moving to a Competitive Low-carbon Economy by 2050.” On one hand, the fiber industry plays a central role in the planned bioeconomy. On the other, this requires a technology push in order to sustainably reduce emissions.

siemens.com/magazine/fiber | 01.2017 Trends

Paper mills

Delivery PixelparkPublicis

Processing, refinement

he roadmap describes a research expedition develop standardized solutions and processes and T into the future. The fiber industry is regarded to take advantage of the opportunities offered by as having the potential to act as a key platform digita lization along the entire value chain. Ultimately, for a number of products on an organic and sustain- it is about more than recycling and new products: able basis as well as for the entire recycling sector. a new climate and energy concept should emerge from Paper is one of the most recycled materials in the the Confederation of European Paper Industries (CEPI) world. According to the Institute of Scrap Recycling roadmap and other roadmaps. Industries (ISRI), in 2015, about 52 million tons of In addition to fibers traditionally extracted from paper valued at US$ 7.7 billion were collected, sorted, wood, cellulose can be extracted from a variety of new and processed in the United States alone. In Germany, sources, and using “waste” such as disposable products, the amount of recovered paper amounted to 15.2 mil- plant residues, milk, or even leather residues will no lion tons out of a total consumption of 20.8 million tons. longer be a utopian vision. The end products of the fiber Using raw materials sustainably is the equivalent industry could replace carbon-intensive products based of creating maximum value from a wood fiber before it on fossil fuels, for example in construction, as sources is used for creating energy at the end of the process. of energy, in the chemicals industry, for packaging, or On one hand, a recycling loop of this kind requires for many other purposes. high-quality virgin fibers allowing such use. On the According to ISRI, using recycled raw materials can other, more and more innovative technologies are nec- reduce energy consumption in production by up to 68% essary in the entire process. This calls for experienced – and thus also achieve cost savings. It’s going to be an and strong partners with the necessary expertise to exciting journey.

01.2017 | siemens.com/magazine/fiber Trends

The new side of lignin

Lignin is seen as undesirable in paper production because it contributes to paper yellowing. To avoid this, considerable chemical effort is required to dissolve it out of wood. However, lignin is one of the most mechanically- and chemically-resistant polymers, and has highly interesting properties.

tora Enso has been con- years now – could you give us which % – % of the lignin S ducting research into lignin an insight into your work and released from the wood needs to for 15 years. We spoke to the particular challenges of this be burned to achieve the high Mikael Hannus, vice president of complex substance? temperature chemical regeneration the Group R&D Innovation at Stora Hannus: Our approach is to find the – of course, that heat is recovered Enso about this. best fit between the natural struc- as steam for power and heat supply Lignin is the second most ture of lignin, the processes we use to the mill and associated energy abundant organic polymer on to extract and separate lignin from markets. earth, exceeded only by cellulose. wood, and, of course, the applica- It is an organic substance which tions for which our customers use What is the value of lignin for causes lignification of a cell when this complex structure of natural the fiber industry and how can it embedded into the cell wall of aromatics. be utilized? a plant. The content of lignin is Hannus: It is important to remem- higher in coniferous trees than Lignin is the second most abun- ber that there are many types of in deciduous trees and it ensures dant organic material on earth. lignin – each with very different high compressive and tensile However, it is far from desirable properties, uses, and values. It is strength in wood. Researchers at in paper production because it only possible to valorize lignins Stora Enso (SE) regard lignin as a contributes to paper yellowing. that are fairly clean and well defined. challenging and complex material To avoid this, great chemical The value lies in the aromatic struc- with application opportunities in effort is required to dissolve it ture, reactive groups in the struc- the construction and automobile out of wood. Do you think the ture, and the size of the natural industries. significance of lignin as a raw aromatic molecule. material for the fiber industry Mr. Hannus, please introduce has been previously underesti- How do you see the fiber industry yourself and provide us with mated and what role will it play developing and how will SE re- a little information about your in the future? align with these developments in role within SE. Hannus: Actually, many forest- order to stay ahead in the future? Mikael Hannus: I’m a pulping based products utilize the benefits Hannus: The demand for fiber technology engineer with the most of lignin – in addition to all solid has seen a healthy growth and we exciting job at Stora Enso – driving wood products, we want to use some expect this to continue thanks to collaboration with our partner of the properties of lignin in maga- global megatrends and the need for universities as well as a number zine papers, fiber-based packaging sustainable solutions in construc- of other interactions around R&D. grades, and in new materials or tion, packaging, hygiene, special chemicals. What is often overlooked chemistry, and the textile industry. You have been researching and is the fact that the chemical recov- We are currently undergoing a trans - examining lignin and its value ery cycle of a kraft mill requires formation in which the declining for the fiber industry for several reaction conditions as a result of share of printing paper business is

siemens.com/magazine/fiber | 01.2017 What trends, innovations, and and innovations, trends, What Hannus: Mikael Hannus,vicepresidentoftheGroupR&DInnovationatStoraEnso source efficiency, high recycling recycling high efficiency, source behind thefirstproductsmadeoflignin topics do you think will deter will think you do topics within the hygiene and textile textile and hygiene the within reduce the need for fossil need the reduce that properties material new rates, industries. applications for special fibers lose fiber meaning steady progress in re in progress steady meaning materials, as well as the emer the as well as materials, mine the future of the fiber fiber of the future the mine being replaced by a growth in in agrowth by replaced being industry in the next years? next the in industry - based packaging and cellu and packaging based Making more from less – less from more Making -based -based - - - - Hannus: customers. gence enormous amount of specialized of specialized amount enormous Hannus: the whole organization is driven by driven is organization whole the the fiber industry? fiber the in developments trend-setting times of changing markets? of changing times innovation. basic How is Siemens establishing establishing Siemens is How How does SE actively promote promote actively SE does How itself as a partner of trust in in of trust apartner as itself

materials we provide to our our to provide we materials

of new services around the the around services new of We invest a lot in R&D and R&D alot in We invest Siemens is providing an an providing is Siemens

opportunities offered by biobased biobased by offered opportunities future and existing the capture tion assets and related services, as as services, related and assets tion well as long as well materials. knowledge in relation to our produc our to relation in knowledge The Vice President of the Group R&D Group of the President Vice The Åbo Akademi University, Finland, and Finland, University, Akademi Åbo Scouting. Hannus is married, has two two has married, is Hannus Scouting. Mikael Hannus Mikael an eMBA from Stockholm School of School Stockholm from an eMBA Energy, Biorefinery and Global Global and Tech Energy, Biorefinery 1997, Since Economics. been has he working for Stora Enso and has held held has and Enso Stora for working positions such as Vice President of President as Vice such positions in Chemical Engineering (1994) Engineering Chemical in from children and lives in Stockholm. in lives and children Innovation at Stora Enso has a Master’s aMaster’s has Enso at Stora Innovation | | 01.2017 siemens.com/magazine/fiber - term collaboration to collaboration term Trends -

Stora Enso The intelligent paper mill paper linerboard a year from around 100 truckloads of recycled paper a day. The brains behind it: the Siemens process control system. Greenpac Mill is a paper mill with the highest degree of auto mation in all of North America. It produces 540,000 tons of Country references:US 100 | | siemens.com/magazine/fiber and several railcars arrive at the mill to deliver waste paper The processcontrolsystemwillprovide a singleviewofthe entirefacility 01.2017

Every day, around trucks

Curtis Schick/Synaptic Digital a day, the equiva a day, the produced are of linerboard tons 1,500 Approximately of rolls. form the out in shipped is that cardboard avery into turned then is This paper. waste deliver to mill the at arrive railcars several and 100 trucks day, around Every offices. their down close or employees off lay to had companies many previously where area an –in here work found already have 135 people growth. further for basis optimal the creates also technology The manufacturing. paper American in milestone logical atechno represents mill 2013, the in Completed cess. pro (old the in boxes) paper recycled use only also but board, packaging lightweight innovative, facture manu not only would LLC Mill Greenpac Subsidiary a constructing 2011 in began and opportunity market a saw quickly Inc. Cascades manufacturer Paper E brand new paper mill in Niagara Falls, New York. New Falls, Niagara in mill paper new brand 50% more 50% can be producedcan paper. from entirely recycled today which box, acardboard in destination very thin cardboardusedfortheflatfacings product ordered online reaches its final final its reaches online ordered product The linerboardmachineproduces lent energy savings through new technology of corrugatedcontainerboard thin but high thin of some 540,000 tons ayear tons 540,000 of some - strength corrugated strength

. - - - ing inverter substation for the paper mill and the the and mill paper for the substation inverter ing ity, Cascades decided to place the entire mill technology technology mill entire the place to decided Cascades electrical and electronic equipment. electronic and That Siemenselectrical overall for the and machine, paper for the operation, energy savings than conventional vacuum pumps. vacuum conventional than savings energy dry the specific industry solutions offered in its Sipaper Sipaper its in offered solutions industry specific the and Siemens with experience had already company the Collaboration by three partners by three Collaboration the pumps consistently provide the exact rate of flow rate exact the provide consistently pumps the sister Cascades medium mill medium Cascades sister wastewater treatment plant located next door at the the at door next located plant treatment wastewater coincidence: no was latter for the responsible be would Siemens used variable speed Siemens used variable line. Siemens supplied the entire power supply, includ- power entire the supplied Siemens line. in a a required by the process and, at low pumping capac- pumping low at and, process the by required Efficiency across the board across the Efficiency large number of pumps. These drives ensure that that ensure drives These of pumps. number large

the hands of just three specialists – for pulping –for pulping specialists three of just hands the

- also consume less power. Other features include include features Other power. less consume also running turbo blowers, which deliver 50% more more 50% deliver which blowers, turbo running | | 01.2017 . - controlled drives for for drives controlled siemens.com/magazine/fiber Country references:US

Curtis Schick/Synaptic Digital “ “Siemens is 700 drives and around 1,000 field devices such as belt belt as such devices field 1,000 around and drives 700 Automation with no ifs or buts or ifs no with Automation Country references:US Greenpac Mill is the paper mill that has the highest highest the has that mill paper the is Mill Greenpac drives to the controllers and the process control system. system. control process the and controllers the to drives Siemens America. of North all in of automation degree duction. Most of the process water is also recycled, with with recycled, also is water process of the Most duction. the biogas generated during treatment suitable for use for use suitable treatment during generated biogas the treatment as well as other waste fiber stock or filling filling or stock fiber waste other as well as treatment where they are thermally recycled. In return, the steam steam the return, In recycled. thermally are they where installed the complete automation system, from the the from system, automation complete the installed steam. for generating afuel as agents are transported to an external power plant, plant, power external an to transported are agents produced is used for the drying process in paper pro- paper in process drying for the used is produced Hewitt, general manager of Greenpac, referring to over over to referring of Greenpac, Hewitt, manager general would stop.” Mill Plant Manager, Greenpac Manager, Plant Mill Murray Hewitt, Murray technology, everything Without automationWithout and process control control and process The plastic that accumulates during waste paper paper waste during accumulates that plastic The | | siemens.com/magazine/fiber really the brains of the mill,” says Murray Murray says mill,” of the brains the really The technologyatGreenpacallows to beasefficientitcan streamlining oftheprocess 01.2017

out aseparate has components of these Each sensors. Learn more about this story andwatch thevideo: aboutthisstory Learn more Greenpac Mill is “truly a smart digital factory facility,” facility,” factory digital asmart “truly is Mill Greenpac thing would stop. There's nothing you can do in this this doin can you nothing There's stop. would thing a a have to is that accomplish to way only “The adds: and from our laptops and even from our smartphones.” smartphones.” our from even and laptops our from only not 24/7 information access to ability the have “We adding: PCS networked lessly PCS Sipaper in block function process manually – it's that automated,” says Hewitt, Hewitt, says automated,” that –it's manually process positioners, ﬂowmeters, temperature, or pressure Harroun, account manager at Siemens, says the the says Siemens, at Robert manager account Harroun, siemens.com/magazine/2w0583 Sipaper PCS auto mation and process control technology, every- technology, control process and mation

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7 total automation solution. automation 7 total 7 process control system. “With- system. control 7 process 7 system, but certainly also also but certainly 7 system, 7 and is part of aseam part is 7 and ”

Curtis Schick/Synaptic Digital Curtis Schick/Synaptic Digital Country references: Canada

New technology for fast corrugation Siemens AG Lake Utopia Paper produces some 185,000 tons of corrugated cardboard annually at a facility in a small town in southeast Canada. When the paper manufacturer wanted to modernize its plants, Siemens was awarded the contract – but a very tight time window allowed only 10 days to implement a complete Integrated Drive System (IDS). A “utopian” idea?

f you follow the course of the Siemens, Lake Utopia was con- I Magaguadavic River, you will vinced by the performance and arrive at St. George, a town efficiency of the Sipaper Sectional with 1,500 inhabitants on the edge Drive System in Niagara Falls, New of the province of New Brunswick York, which is operated in a sim- Integrated drive solution in southeastern Canada. Here, in ilar manner. For the moderniza- for paper machine and mill the immediate vicinity of pictur- tion of the paper machine and mill, ◾ esque Lake Utopia, the paper Siemens also relied on products 1 modular solution consisting of manufacturer of the same name from the Sipaper and Integrated 25 Sinamics S120 cabinet modules produces thousands of tons of cor- Drive Systems portfolio, devel- ◾ 4 Sinamics drives rugated cardboard annually for oping a precisely adapted drive ◾ packaging products for customers solution. The Sipaper Advanced 23 Nema motors with an output in Canada, the USA, and Latin Process Library (APL) enabled a of 30–300 hp America. The company is part of fast, cost-effective, and modular ◾ 5 Simatic TP1500 Touch Panels the J.D. Irving Group, one of the implementation. ◾ largest employers in the region, During the 10-day turnaround, 1 Simatic PCS 7 engineering and and has been a successful enter- four Siemens experts worked on operator station prise since its founding in 1882. commissioning the paper machine. ◾ 1 Sipaper PCS 7 master controller In order to continue to operate Not only the quality of the tech- sustainably and reliably and be nology, but also the expert indus- able to meet the needs of its cus- try-specific knowledge Lake Utopia tomers into the future as well, in Paper has trusted for more than 2014 Lake Utopia Paper decided to 25 years was decisive. This allowed ernized drive solution made it modernize its paper mill. As part of the modernization to be imple- possible for Lake Utopia Paper to a comprehensive solution, Siemens mented in a timely manner despite increase plant availability and the was commissioned to upgrade the extreme time constraints: “Siemens quality of its products, reduce paper machine drive system to closely monitored engineering, downtime, and optimize energy reflect the latest technological stan- installation, and testing to ensure consumption. “After implementing dards. The catch: in order to avoid timely completion, which was very the Siemens solution, we were able downtime, only 10 days were sched- important for the overall success to boost the speed of our paper uled for project implementation. of the project,” says Justin Legere, machine to increase daily produc- project manager at Lake Utopia tion,” explains Legere. In specific A narrow time frame Paper. terms, the paper machine is more for powerful technology than 30 meters per minute faster This was a real challenge for Corrugated cardboard than before – helping achieve a trusted partner Siemens, which by the meter higher production of corrugated had already demonstrated its In St. George, the paper mill is now medium. expertise in advance: Prior to operating again – and even more the contract being awarded to effectively than before. The mod- siemens.com/magazine/lakeutopia

01.2017 | siemens.com/magazine/fiber Churning Each day Schoellershammer GmbH & Co. KG Co. & GmbH Schoellershammer day Each out paper out paper Germany-based company one of the leading producers of corrugated cardboard. per paper of kilometers 1,500 roughly produces consumer goods manufacturers. goods consumer and chains food fast international as e-commerce in boom the include The 2.9%. up to by increase will ucts prod tissue/hygiene and material for packaging demand yearly and will board, and cardboard in particular paper,tissue corrugated card for demand the Consulting, ment Manage Pöyry by published study Country references:Germany GmbH & Co. KG in December 2016. December KG in &Co. GmbH developments and other factors, factors, other and developments operation at Schoellershammer the new PM 6 corrugated cardboard cardboard 6corrugated PM new the thin packaging paper with low with paper packaging thin with a net working width of 5.60 of 5.60 width working anet with mented within a very short time time short avery within mented meters. produced are testliner and medium corrugating 6, PM the On industry. long It is designed for manufacturing for manufacturing designed It is base paper machine was put into put into was machine paper base basis weights, thus following the the following thus weights, basis D well as growing demand from from demand growing as well The PM 6 project was imple was 6project PM The In response to these worldwide worldwide these to response In siemens.com/magazine/fiber reasons for this are believed to to believed are for this reasons increase even further by 2030, 2030, by further even increase - term trend in the packaging packaging the in trend term paper machine. This makes the Düren, According to an insight insight an to According worldwide. growing is board emand for paper and card and for paper | | 01.2017 - - - - - Voith Paper GmbH & Co. KG, and KG, and &Co. GmbH Paper Voith technical contact. Voith supplied supplied Voith contact. technical Achieving success with success Achieving The innovative Sipaper Drives APL APL Drives Sipaper innovative The The standard components of the the of components standard The control system, and the covering, covering, the and system, control configured to the requirements of requirements the to configured together, smoothly work combined, voltage motors are optimally optimally are motors voltage cabi control converters, voltage the paper machine, including the the including machine, paper the the Sipaper portfolio from Siemens Siemens from portfolio Sipaper the that all components such as low as such components all that the PM 6. Industry 6. PM the tion and control functions of the the of functions control and tion software standard dovetails per dovetails standard software with TBP Piesslinger GmbH as the the as GmbH Piesslinger TBP with Sinamics S120, ensuring consistent consistent S120, ensuring Sinamics Sipaper solution are individually individually are solution Sipaper and Schoellershammer relied on Schoellershammer and machine the processing, material Sipaper Drives APL software stan software APL Drives Sipaper for the integrated drive solution. drive integrated for the fectly with the drive technology of technology drive the with fectly and enable even simpler operation. operation. simpler even enable and low corresponding the and nets, (Integrated IDS This increases. period by Siemens together with paper quality even as throughput throughput as even quality paper Drive Systems) solution ensures ensures solution Systems) Drive integrated drive systems - specific regula specific

------All-in service service All-in With Simatic Virtualization as as Virtualization Simatic With dard deliver the best possible con possible best the deliver dard decoupling the oper the decoupling trol quality with a significantly asignificantly with quality trol ating system and and system ating mentation of virtuali- mentation imple simple offers also a breaks. web of paper risk reduced zation solutions by solutions zation Service (SIVaaS), Siemens Siemens (SIVaaS), Service A standardizedIDSSipaper greater productioncapacity corrugated cardboardbase drive paper Schöllershammer GmbH & Co. KG solution ensuresthePM6 machine canachieve - - - paper machineat SchoellershammerGmbH&Co.KG About 1,500kilometersofpapera dayisproducedper 1,500 km process. The resources hardware can be used optimally, and system system and optimally, used be can consolidating them within virtual the user software for the drive drive for the software user the upgrades and updates can be car be can updates and upgrades solution from the hardware, and and hardware, the from solution required and the likelihood of not is training system further addition, In easily. out more ried maintenance of the production production the of maintenance and diagnostics, management, centralized allows This machines. - 10,000 tons of saleable paper. of saleable tons 10,000 concept. Deploying a standardized astandardized Deploying concept. operating errors is minimized minimized is errors operating the machine already produced produced already machine the operating auniform to thanks system at any time, allowing it to it allowing time, any at system Schoellershammer can expand the the expand can Schoellershammer remain flexible. In January 2017 January In flexible. remain interface problems will occur. PCS

siemens.com/ids

7 system also means that no that means also 7 system | | 01.2017 Country references:Germany siemens.com/magazine/fiber

Publicis Pixelpark Country references: Austria

Bright prospects

Laakirchen Papier AG (LPA), a producer of natural paper based in Upper Austria, is taking advantage of the changes that have become necessary in the industry: in the future, it will not only be involved in the growth market for packaging paper, but will also be setting its sights on becoming a digital enterprise.

agazines, catalogs, adver- improve its operations manage- M tising flyers – many print ment – specifically the Simatic PCS 7 products have been an control system. Now this Siemens essential part of our daily lives technology will help Laakirchen for decades. However, due to the Papier complete the transformation ongoing trend toward digitaliza- from a fiber industry player to a tion, more and more print media is digital enterprise. disappearing with the emergence of online media. According to A virtual environment Laakirchen Papier, since 2008 the for energy control systems market in Europe for high-gloss Since October 2016, Laakirchen magazine paper for printing maga- Papier has been using the Siemens zines, newspaper supplements, and solution to visualize the energy advertising materials has declined control system of its processes in by 25%. However, for the Upper a virtual environment provided by Austrian manufacturer of supercal- LPA. This enables the company to endered natural paper (SC paper) increase the performance of the that is no reason to bury its head plant and, thanks to the redundant in the sand. LPA is implementing server structure, minimize down- a strategic change to remain viable time. In addition, LPA is reducing into the future. For years the computer hardware costs: small paper manufacturer has relied on thin clients with 24-inch flat Siemens automation technology to screens have taken the place of

siemens.com/magazine/fiber | 01.2017 The companymanufactures550,000tonsofpaperannuallyontwomachines,thePM10andPM11 toring of the control system. The system. control of the toring moni performance control using maintenance and for optimization measures timely and targeted tiate ini can operators plant down, goes loops control of individual mance perfor the if For example, beneﬁts. operators. and for users of use ease ensuring tors, moni large with equipped tions worksta at computers individual advanced process control (APC) (APC) control process advanced is PCS 7 offers a wide range of range awide 7offers PCS function block library. With With library. block function

already a part of the standard standard of the apart already advanced control methods methods control advanced such as multi as such trol and predictive control predictive and trol lers, the Simatic Controller Controller Simatic the lers, not only offers important important offers not only features for improving for improving features plant efﬁciency and and efﬁciency plant productivity but also but also productivity - variable con variable ------into the future the into break to decided also Laakirchen market, the to services and ucts of prod range diverse amore offer to areas economic and social, trial, indus all in for companies crucial it makes digitalization Because facturing of high facturing manu the is one areas: core two on paper producer therefore focus will the future, the In market. paper in for retail qualities paper in more even specialize will we means This demand. constant ensures rials mate advertising printed in trade the “At present, focus: its changing is company the explains, Lunabba AG Mark Papier of Laakirchen CEO As paper. SC in position market its secure to step important an taking is Papier Laakirchen year, This future the in Investing environ of the protection and safety plant to contributes packaging. for demand increasing meet to cardboard corrugated lightweight of production the other the and

siemens.com/pcs

the future.” But that is not all. not all. is that But future.” the | | 01.2017 siemens.com/magazine/fiber - oriented packaging packaging oriented - quality SC paper paper SC quality ment.

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Laakirchen Papier AG

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