A Royal Event for Board and Packaging Papers

Home , Folding boxboard, Solid bleached board

In early May 2001, under the motto “ahead, Voith Paper invited the manufacturers of board and packaging papers to Vienna to exchange their experiences and opinions.

The list of the more than 400 participants reads like the ‘Who’s Who’ of the board and packaging paper industry: The author: Over 250 top international managers Nicole Schnait, from the board and packaging paper Paper Machines Board and Packaging sector, as well as representatives of institutes, technical universities and representatives from the media had accepted the invitation to come to Vienna. A total of 40 countries were represented – from Australia to Canada, from Japan to Chile. Otto Heissenberger, President of the Board and Packaging 3 Paper Machine Division, and Dr. Hermut Kormann, Lunch was served in the newly renovated President of J.M. Voith Aktien- roof foyer of Vienna’s Hofburg Palace. gesellschaft, Heidenheim.

Vienna’s Hofburg Palace provided a royal setting for the conference. In former times, the Hofburg Palace was the emperors’ winter residence. Today it houses the offices of the Austrian Federal President, the Spanish Riding School, the National Library, several museums and a modern conference centre. More than 350 guests from 40 countries attended the conference held in the ‘Großer Redoutensaal’. 4

On the evening before the conference, Otto Heissenberger, President of the Board and Packaging Paper Machine Division, welcomed the guests at a reception held at the Ferstel Palace. The evening’s entertainment was an 5 experience enjoyed by everyone. In the A ‘gemutlich’ evening at a ‘Heuriger’ with relaxing atmosphere, many attendees The spouses’ programme included a visit to typical ‘Schrammel’ folk music is an absolute also found the time to discuss future the imperial apartments in the Hofburg and the must in Vienna. plans and projects. Porcelain Manufactory Augarten.

Three years had passed since the last What are the possibilities of multi-ply SAICA 3 in Spain, the fastest paper ma- “ahead Customer Conference was held in and multi-layer concepts, when are chine for corrugating medium, constantly 1998, focusing for the first time on the such concepts used today and what reports new speed world records. The topic of board and packaging papers – advantages do they offer for the pro- new production line for gypsum-grade and it was time for an update. duction of certain board or packaging paperboard, Lawton, Oklahoma, USA, is paper grades? the world’s first paper machine fitted with two gap formers. The fact that the Many investments were made by Voith What can be done to follow the trend shoe press technology has also gained a Paper during these three years, mainly towards higher speeds and lower basis firm foothold in the production of board to strengthen its process competence. weights of packaging papers? What was demonstrated by a report on the Today, papermakers have to re-think and are the possibilities to boost produc- BM 3 rebuild at Mayr-Melnhof, Frohn- optimize their complete production tion while enhancing quality when leiten, Austria. process to assure that their products are producing board? geared to market requirements at optimum cost effectiveness. How do investment cost and operating The guests’ expectations were high, and cost correlate, and how can a the participants this year were twice as machine’s total cost be minimized? many as during the “ahead 1998 Confer- Some changes were clearly visible, such ence. The numerous positive reactions, as the acquisition of the Scapa group, The papers focused both on concepts for the pleasant atmosphere during the con- which considerably strengthened the new production lines and on possible ference and the fact that the large confer- Voith Paper Service Division and made upgrading through rebuilds. Moreover, ence room was packed full until the last Voith Fabrics one of the major manufac- several “smart solutions” were present- paper was read, showed that the Vienna turers of paper machine clothing. ed, allowing the papermaker to achieve conference was worth visiting. lasting improvements in machine performance with small investment budgets In other areas, such as research and de- and minimum amortization times. In closing, a small, but unique, thank- velopment, Voith Paper has also focused you gift was presented. Each participant on strengthening its process compe- received a ‘take-away’ paper machine. tence. The following topics were inter- Highlighted on the agenda were the pa- The simple design, ab- linked throughout each paper being pre- pers on new reference plants. During solutely maintenance- sented at the “ahead 2001 Conference: “ahead 1998, several new components free and environ- and machine concepts specifically devel- mentally friend- oped for board and packaging papers had ly, was received How do the raw materials used, the been presented, such as the gap formers, with great enthu- stock preparation equipment, the DuoFormer™ Base and DuoFormer™ Top. siasm. paper machine components and fol- This time, five customers demonstrated lowing process stages interact with how these concepts had successfully “ahead on the Internet: one another during operation of a been put into practice, giving current fig- All papers and the best photos of the conference board or packaging paper production ures to substantiate their reports. can be found on the “ahead homepage: line and how can such interaction be Simply download at: www.ahead.voithpaper.com utilized to achieve an optimum The papers presented at the conference can also be requested from: product? Some of the production lines discussed Ms Sigrid Hrebacka, Fax: +43 27 42 8 06 25 48 have revolutionized the industry: PM 9 at E-mail: [email protected] 6

Our guests’ opinions

Ing. product. It was a highlight for me not Henk Lingbeek only in technical respects, but also be- SCA Packaging De cause it focused on the tasks of our Pekka Mauranen Hoop, Netherlands product. KCL, Finland

It was an excellent conference, and what ... Whether I will come again? Yes, of I come from the Finnish research insti- I liked especially – I also attended the course, we already agreed yesterday that, tute KCL and have to admire your team. conference three years ago – was the if things go on like this, Voith can hold Listening to all of the papers about the combination of topics: not only technical such a meeting every week! different products, I realize how deep issues, but also some dealing with mar- their expertise is in this field. keting, final products, Voith Paper's philosophy and organization. I think Voith has done extensive theoreti- cal research and development work and has applied the results in practice on the pilot machine and in customers’ mills… Peter Reichler Amcor Australasia, ...Of course, the location is very impres- Australia sive, this imperial palace...

Dipl. Ing. (FH) I think it was a very impressive confer- ...I think it's a world-class conference! Manfred Stemmer ence, you have picked a beautiful loca- Cascades Arnsberg tion, even the weather is impressive. GmbH, Germany What pleased me more than anything else was the quality of the presentation and My general impression is a very positive the information provided... one, we gained new ideas and thoughts, and moreover, it was a good opportunity ... It was very pleasing that the informa- to talk with many colleagues. tion was prepared in a way that even the non-technical people, such as myself, T.S. Ong What impressed me most was the profes- could understand... Genting Sanyen, sionalism of the presentations. Malaysia ... The paper on investment and operating ...An important thing is that people with cost yesterday and of course the two pre- The conference was well organized, and I practical experience were present, report- sentations of the new mills in Turkey and think the topics were well chosen, partic- ing about their experiences... SAICA were most interesting!… ularly on the first day. The quality of the papers, in general, was good – ’they were ...What I also liked very much, as I come ...I do have to express my appreciation of presented by many of the young people. I from the folding boxboard sector myself, the Voith team – they have done a fabu- think there is a bright future ahead be- was the first paper giving entirely new lous job! cause Voith is capable of renewing itself aspects of the publicity value of our with these young specialists... News FROM StoffaufbereitungTHE DIVISIONS 7

Stock preparation – the key to ensure the productivity of newsprint and SC paper machines

The Federal Republic of Germany holds What is the present situation in the use a top position in Europe with regard to of recovered papers in the field of graphi- the use of secondary fibers for the man- cal papers? ufacture of paper and board products. The rate of utilisation of recovered Fig. 1 shows the relative recovered paper paper is presently 62%. For Germany, contents for the most important graphi- this ratio is expected to be increased cal, wood-containing paper grades. The further, which will lead to a further abscissa in this diagram represents the reduction in fresh fiber usage. quality whereas the ordinate stands for The author: the price achieved with these products. Harald Selder, The red field describes the average, rela- Fiber Systems tive recovered paper content used in It is known that the largest quantities of these products. recovered paper are used in the field of packaging papers. In this product sector, Today, the standard newsprint paper is signs of maximization have already be- usually made from 100% deinked pulp come apparent, so that in this sector no (DIP). The same applies for upgraded increase in the use of recovered paper newsprint. In the SC paper sector, 40% is to be expected. A higher percentage of secondary fibers are used on average, can therefore only be achieved by raising and for LWC papers, approximately 25%. the secondary fiber usage for graphical A similar percentage is also used for the papers. high-grade coated papers. 8

Fig. 1: Content of deinked pulp in wood-containing printing papers.

Fig. 2: Number and relative weight of advertising inserts in newspapers.

Weight of inserts *Relative weight = x 100 Overall weight (newspaper + inserts)

Fig. 3: Trend in paper grades used for magazines and change in inorganic content of DIP. German deinking furnish: 50% ONP, 50% OMG.

1 Recovered paper: share of 70%. In Japan, statutory regula- 100 quality and availability tions limit the advertising space in daily HWC newspapers, which explains this high MWC The recovered paper grade, which is percentage of inserts. 75 LWC available in sufficient quantities in Ger- many and of satisfactory quality unifor- Such a high share of inserts is not to be MFC mity, suitable for the higher-quality, expected in Europe. However, a further STIN 50

Price graphical papers, is the deinking furnish. increase in the number of advertising in- SC serts in daily papers is to be reckoned SIN This deinking furnish is collected in the with. Local and regional advertising is not 25 IN form of a household collection grade by of interest as yet for the electronic media, Rel. content of deinked pulp [%] NEWS the recovered paper trade, and it‘s then and it will remain a domain of print ad- separated into brown and white paper vertising for now and the near future. Quality fractions in sorting plants. Another change can be noted for the 2 30 80 The resulting white paper fraction con- magazine paper grade. Approximately sists of approximately 50% old newspa- 15 years ago, the principal paper grade 70 25 pers and 50% magazines and is supplied for magazine production was LWC paper. Japan 60 to the paper mills as deinking furnish. Today, the predominant paper grades Japan 20 The paper composition of this deinking used for magazines in Germany are the 50 furnish is subject to continuous change, SC paper grades suitable for roto-gravure 15 40 which the stock preparation engineers printing, as can be seen from Fig. 3. have to take into consideration. In this About 70% of the magazines published 30 10 Germany article, we will point out the most essen- in Germany are presently printed on SC 20 tial changes in the deinking furnish com- papers. Germany 5 position, which have an influence on the Number of inserts 10 Relativ weight* [%] deinkability and the DIP quality. This situation must be expected to 0 0 change again. The reason is the new gen- Today, the daily newspapers include ap- eration LWC papers. These papers are 3 proximately 2-5 advertising inserts per coated and calendered in an online 100 50 paper. These inserts are in most cases process. In this way, production costs printed on SC and LWC papers. The can considerably be reduced. In addition, 80 40 printing process is mostly sheet-fed off- the quality of these papers is equivalent SCA Papers set with integrated heat-set drying. Due or even superior to that of the corre- 60 30 to this heat-set treatment, many prob- sponding SC papers. Consequently, there lems have to be reckoned with when it will be more LWC papers in the deinking Ash content comes to deinking. The quantitative share furnish in the future. 40 20 of these inserts is approximately 10-20% LWC Papers of each newspaper, as shown in Fig. 2. From Fig. 3, it is also obvious that a con- Relative content [%] Relative 20 10 stant rise in ash content can be noted in In Japanese daily newspapers up to 30 the deinking furnish. This rise is the 0 0 Content of anorganic substances [%] inserts per distributed paper can be result of continuously increasing ash 1985 1990 1995 2000 2005 found. In this case, the inserts have a contents in LWC and SC papers, and on Fiber Systems 9

– Higher final – Runability product requirements – Productivity – Quality decrease of recovered paper Fig. 4: Runnability- and productivity-related 4 – Reduction of fresh variables. water consumption Fig. 5: Simplified block diagramm of analyzed system. the other hand of rising ash contents in 5 analysis focused on establishing the standard newsprint papers. Drum pulper change in the macro and micro stickies area. For reasons of completeness, the Drum chest Along with the higher percentage of mag- development of the chemical oxygen de- azines in the deinking furnish, more ad- Coarse screening mand and the anion-charged substances

hesive glue and more hotmelts are auto- Loop I was also established. matically fed into the stock preparation Flotation I systems. These substances are the Fine screening For the macro stickies determination, the sources of the macro stickies, which will pick-up method, developed by Voith Sul- Thickening I cause many upsets on the paper machine zer was used. And, the micro stickies if not sufficiently removed. In addition, were determined with the laser optical Disperging I large quantities of coating binders and particle counting method developed by coating additives are included in the Flotation II BASF. coated papers. It is from these sub- Thickening II stances that the micro stickies originate Loop II In the following section, a thorough de- resulting in serious runnability and avail- Make up scription is given of the results obtained ability problems on the paper machines water from PM regarding the macro and micro sticky be- if their removal is not satisfactory. This haviour. Disperging II H2O2 situation will require systematic counter- NaOH measures in the future (Fig. 4). Bleach tower Results In addition to the usual targets of optical brightness and cleanliness, which are preparation systems with regard to the Macro stickies aimed at in the stock preparation separation of detrimental substances. For The first reduction in macro stickies process, the separation of detrimental this reason, the results of a detrimental worth mentioning occurs in coarse substances in the recovered paper must substances analysis will first of all be screening, as shown in figure 6. In flota- also be increasingly considered in the fu- presented. tion I, no macro stickies are removed. ture. As fresh water usage in paper pro- With 85% removal efficiency, fine screen- duction is reduced, this subject becomes The system chosen for the analysis ing is by far the most effective process even more important. The remainder of (Fig. 5) consists of a 2-loop process for module. A further reduction in macro this article describes solutions for the the production of DIP for SCB papers. stickies can be noted in both disperging control of detrimental substances in the The first process loop includes the drum systems. stock preparation system. The control pulper, coarse screening, flotation I, fine strategies are integrated with plans for screening, thickening and disperging I. The total sticky loading was reduced from optimizing paper machine operation. The second process loop contains flota- 11510 mm2/kg b.d. to 192 mm2/kg b.d. tion II, thickening and disperging II. Dis- which corresponds to a total reduction of perging II is combined with peroxide 98.3%. Process modules for controlling bleaching. No process water cleaning is detrimental substances connected, neither in the first nor in the Micro stickies second process loop. Only the make-up The change in micro stickies area in each In order to be able to fight detrimental water from the paper machine, which is process step presents a completely dif- substances effectively, it is necessary to carried over to the stock preparation, is ferent picture from that of the macro define those modules integrated in stock run through a microflotation. The system stickies. The screens do practically noth- 10

After pulping 10 = inlet coarse screening 11510 4.71*10

Inlet flotation I 4000 1.02*1010 After flotation I 4849 10 = inlet fine screening 8.44*10 Fig. 6: Change in macro stickies area in the analyzed deinking system. After fine screening 725 9.19*1010 Fig. 7: Change in number of micro stickies in the After thickening I 10 analyzed deinking system. (MC+HC) 1180 3.78*10 Fig. 8: Effectiveness of stock prep process units After disperging I 600 4.23*1010 in removing substances detrimental to runnability and productivity. Inlet flotation II 436 9.77*1010 Fig. 9: MultiScreen fine screen optimized for macro stickies removal. After flotation II 10 520 6.32*10 Rotor – Multiple blades After thickening II 10 – Adequate pressure pulses 580 3.01*10 Screen basket – C-bar™ technology After bleach tower 10 330 3.43*10 – High precision of slot width Housing Headbox PM 192 6.26*1010 – Conical design – Fishmouth accept discharge 10 10 0 4000 8000 12000 0 4*10 8*10 Macro stickies area [mm2/kg b.d.] Number of micro stickies [n/kg b.d.] ing in terms of micro sticky removal. 67Whereas the flotation blocks possess a 8 Process blocks Macro stickies Micro stickies COD Cationic demand considerable separation ability. A high re- Coarse screening moval efficiency is produced in the thick- Flotation I ening stages. But, the low micro sticky Fine screening level after the thickening processes can- Thickening I not be maintained due to the highly cont- Disperging I aminated process water that is subse- Flotation II quently used for dilution. At this point it Thickening II becomes noticeable that microflotation is Disperging II needed for cleaning the process water No influence Low improvement Medium improvem. High improvem. (Fig. 7).

9 Rotor Fig. 8 summarizes the efficiency of the individual process modules used in the stock preparation system with regard to the separation of the investigated group of detrimental substances.

The most effective process module with Inlet Screen basket regard to macro sticky separation is fine screening. Voith Paper Fiber Systems recognized the importance of fine screening for the macro sticky removal at an early stage and now offers a most effective machine – the MultiScreen. This screen (Fig. 9) is completely optimized Reject Housing from “head to foot”.

Micro sticky control is most effective in the flotation blocks and in microflotation used for water cleaning. However, there Dilution water Accept will always be some residual micro sticky load carried over to the paper machine. Fiber Systems 11

11502% 1300 Fig. 10: Correlation between build up of 1100 detrimental substances in the PM white water. absorption efficiency and fresh water usage. 0% 900 Fig. 11: Effect of hydrophobic micro stickies 10% 700 concentration in the process water loop on paper machine availability. 500 25% Change in Fig. 12: Strategy for control of detrimental 300 50% 75% Absorbtion efficiency substances.

detrimental substance [%] Process units relevant to macro stickies 100 100% Source: BASF Process units relevant to micro stickies 071421 Process units relevant to COD Process units relevant to cat. demand. Fresh water l/kg paper 10

In this case, the carried over micro sticky 11 Feed quantity of micro stickies Collapse situation = load is to be bound to the fibers by > rejected quantity renew process water means of fixing agents so that the left- over microstickies go out with the finished paper. The correlation between absorption efficiency and changes in concentration dependent upon fresh water usage is shown in Fig. 10. It can be noted that a 50% absorption efficiency is required for maintaining a stable micro sticky concentration in the white water Concentration of hydrophobic circuit (Fig. 10). micro stickies in process water

Feed quantity of micro stickies = rejected quantity Machine uptime If more micro stickies are fed to the paper machine than can be absorbed by the 12 fiber material, the concentration in the white water circuit will continuously rise. Eventually, a critical concentration is Stock preparation Paper machine reached where slight changes in temperature and pH-value will induce the formation of macro stickies due to displace- ments in solubility. With a further increase in concentration, a collapse situa- Minimization of tion will be evoked. The paper machine Mikro- flotation I carry over must be shut down and the process water exchanged. This kind of situation will Mikro- flotation II considerably impair paper machine availability (Fig. 11). Flotation I Fine screening Coarse screening Thickening I Thickening Thickening II Disperging I Flotation II Summary and recommendations Disperging II Optimum reduction in Fixing of residual detrimental substances detrimental substances to the fibre and removal with the paper In order to ensure the runnability and availability of high-speed newsprint and SC paper machines, it is absolutely nec- detrimental substances by a correspond- Consequently, deposits and contamina- essary to control the level of detrimental ing module arrangement and by opti- tions of felts and screens can be elimi- substances. There is a continuously in- mized process water management and nated. Another advantage of this control creasing load of detrimental substances, cleaning. The aim should always be to strategy is the much reduced usage of and countermeasures must be taken to keep the carry over of detrimental sub- process chemicals during the manufac- fight this. Detrimental substances are stances to the paper machine as low as turing process. Fixing agents should only combatted most efficiently in the stock possible (Fig. 12). This way, high con- be used after the reduction in detrimental preparation systems. The system supplier centrations of detrimental substances in substances in the stock preparation sys- can decisively help to reduce the load of paper machine circuits can be avoided. tem has been optimized. 12

New EcoMizer™ – Product A new cleaner concept establishes itself

Hydrocyclones for the separation of specifically heavy and/or light contaminants have been used in the paper industry for about 50 years. After some significant innovations in the first decades, the development of hydrocyclones came to a relative standstill in the recent past. Consequently, the difficulties with these machines have The author: remained the same. The new EcoMizer Wolfgang Mannes development now offers a solution to Fiber Systems many of these problems. Fiber Systems 13

Fig. 1: Distribution of axial velocities in a hydrocyclone (result of numerical simulation using the finite volume method).

Fig. 2: Backflow of thickened, contaminated suspension in the vortex center.

Fig. 3: EcoMizer™-Cleaner – Flow conditions at the rejects outlet.

Thickening behavior as a basic problem large influence on the viscosity – the 1 vax (m/s) more energy is required for this. 9.65 Most problems with hydrocyclones can be contributed to an elementary cause – In the hydrocyclone, energy is fed in with 6.89 the tendency of the fibres suspension to the incoming suspension only and dis- thicken in the rejects. If this tendency is tributed downwards in the hydrocyclone 4.12 not correctly assessed when designing a by the axial flow running along the cylin- 1.36 cleaner plant, stock consistency increas- der and cone walls (Fig. 1). This energy es in the final stages of a cleaner plant distribution depends on the volumetric -1.39 will lead to operating problems and/or distribution of the inlet flow into the ac- excessive fibre losses. cept and reject flows. -4.16

However, apart from the uncertainty in The lower the volumetric reject dis- -6.92 the design of cleaner plants, fibre thick- charge, the less energy reaches the bot- ening also limits the possible operating tom cone area. At the same time, the 2 conditions. A hydrocyclone only func- stock consistency, and thus the viscosity Cleaner cone tions with the use of fibres while their of the suspension, are at its highest in fluidation caused by rotation is guaran- the bottom cone area due to the thicken- teed. If the rotation in the cone comes ing effect of the hydrocyclone. Therefore, to a standstill, the cleaner becomes with low reject rates, failure of the re- clogged. The restriction at the cone noz- ferred to rotary motion may occur and Backflow zle or a re-routing of the rejects on the consequently lead to clogging of the cone end to a radial or tangential outlet, cleaner. Nozzle will not allow any “pressing through” of the fibres. The consumption of the kinetic energy in the cone area is further intensified by an This phenomena of rotation failure actu- additional phenomenon. As can be seen ally is the most common cause for oper- in Fig. 2, the basic pattern of a downward ating problems on the hydrocyclone, flow along the cone wall and an upward whereas clogging due to individual, or back-flow in the vortex centre is also 3 large-size contaminants is rather an ex- present at the reject outlet. ception in the low consistency range. With this backflow, the thickened reject stock is returned to the cone where it fur- Break-down of rotation and return flows ther increases the consumption of kinetic energy. In addition, contaminants, which What causes the rotation in a hydrocy- were already separated, are once more clone to break down? Since a fibre sus- entrained upwards and in the worst case, pension is a viscous medium, it must be may even reach the accepts. constantly fed with energy in order to maintain the rotation in the cleaner. The more viscous the medium – as is known, the stock consistency of fibres has a very 14

Fig. 4: Problems with classical concepts for rejects dilution.

4 Low addition of High addition of Distribution dilution water dilution water of axial velocity

upwards

downwards

Contaminants settle back Danger of backflushing to the cone wall the contaminants

The EcoMizer™ concept In conventional concepts to decrease the near the cone wall, where the contami- reject stock consistency, the filtrate is nants are concentrated, are not affected The newly developed EcoMizer concept usually added tangentially in the lower at all by to the addition of dilution water, offers a solution for these two problem cone area (Fig. 4). Although fibre recov- which also facilitates the dosage of the areas. The concept was derived from the ery is thus fundamentally possible, with water quantity. fact that the basic flow pattern in the hy- an excessive dosage of filtrate there is a dro-cyclone cannot be influenced. This is great risk that contaminants, already con- Finally, the energy demand for adding the a consequence of the geometry and the centrated in the cone wall area, will be di- filtrate is considerably lower than when it usual distribution of the volumetric inlet verted to the vortex center at the point is carried out via the cone wall. Depend- flow in a hydrocyclone. However, the where the filtrate is fed in. If these conta- ing on the pressure ratios in the hydrocy- decisive idea is to “replace” the thickened minants reach an area with an upward di- clone, even a vacuum may exist in the reject stock in the central return flow in rected axial speed, flushing back of cont- vortex centre, so that the flushing water the lower cone by a clean filtrate or white aminants into the accepts may occur. is sucked in from the outside without any water added from the outside (Fig. 3). This risk particularly exists for contami- pressure. Thus, on the one hand, dirt is prevented nants which are difficult to separate, from being sucked upwards once again. such as dirt specks, since their specific In conclusion, it is possible with the On the other hand, the injected filtrate weight differs only slightly from that of EcoMizer concept to decrease the stock will mix in the cone with the surrounding fibres. consistencies in the reject outlet area suspension, so that the stock consisten- without any negative effect on separation cy of the surrounding suspension will With the EcoMizer concept, however, the efficiency. On the contrary, due to the also be decreased. addition of the filtrate is distributed over fact that the thickened reject stock is pre- a comparatively large volume, actually vented from flowing back in the vortex the entire lower cone area. Thus, it can centre, and because of the lower stock Comparison with traditional concepts be dosed much better. consistencies, the rotational speeds in the lower cone remain high and the trac- This type of dilution water addition has Furthermore, addition of filtrate is started tive forces acting on contaminants re- several advantages compared to previous in the centre of the cleaner and from main low. This means efficiency may concepts. there continues outwards. The layers even be improved in certain cases. Fiber Systems 15

Accepts

Fig. 5: Advantages of the new EcoMizer cleaner concept. Inlet

5 of the rejects, the stock consistency in Higher operational reliability at lower reject rates the bottom cone area still remains lower than with conventional cleaners. With Reduced number of cleaning stages (2-3 in stock preparation, higher inlet stock consistencies, new max. 4 in the approach flow) possibilities result concerning the Savings with respect to space require- arrangement of fine cleaning and slotted ments and additional investment costs for screening in recycled paper stock prepa- pumps and drives, piping and control ration systems. equipment

Reduced energy consumption for pumping Finally, contaminant concentration can Improved dirt speck removal now be increased with continuous reject Efficient sand removal at considerably discharge in the final stage to such an higher consistencies than previously extent as was previously only possible possible with periodically rejecting final stages. New possibilities in the process design Through minor changes to existing sys- Reduced fiber losses through higher tems, considerable reductions in losses contaminant concentration in the rejects and thus a lot of savings in the currently incurred disposal costs have already been achieved. What advantages result? (Fig. 5) This list gives a first idea of the potential The operating reliability of cleaner plants inherent in the newly developed technolo- is always increased by lowering the stock gy presented here. The improvements are consistencies in the lower cone area. In not just a small step forward, they are addition, back flushing allows operation more like a quantum leap. of a cleaner with lower volumetric reject rates and lower reject stock consistencies. It is thus possible to design the fol- Where are the limits? lowing stages considerably smaller than Rejects before. Consequently, the required num- To be honest, we do not know yet. It will ber of cleaner stages is substantially surely be an exciting task for the future reduced, providing large savings, both in to answer this question. In the almost Dilution the overall infrastructure required for op- 20 installations, which have gone into operating a cleaner system, as well as in eration since the first application in a pumping energy. plant approx. 1 1/2 years ago, the limits have not yet become evident. In most Higher separation efficiencies for conta- cases, start-up caused no problems minants, which are difficult to remove, whatsoever, enabling the customers to like dirt specks, have already been men- profit immediately from the significant tioned. Alternatively, the cleaners can be advantages of a higher operating reliabili- operated with higher inlet stock consis- ty with simultaneously improved accept tencies than before, while maintaining the quality and/or reduced fibre losses by up previous efficiencies. Due to the dilution to 70 %. 16

Get the most out of your fibre

1 One-ply concept Multi-ply concept Topliner Underliner

Filler

Backliner

Solid Bleached Board Folding Boxboard, White lined chipboard (typical for USA) (typical for Europe, Asia) The author: – fully bleached (kraft) pulp – fibre stock acc. to ply requirements Dietmar Borschke, – high freeness – low freeness Fiber Systems – high E-modulus/stiffness – bulk filler for high board stiffness – high furnish costs – high investment and low furnish costs – low investment costs

Multi-ply sheet formation allows the ply and is usually produced from shining through, striking through or board to be provided with a great bleached kraft pulp. This simple sheet pressing through of the filler material. number of special features by selecting formation is compensated by the excel- For the filler ply, stock mixtures of high special fibres and mixtures for the lent fibre properties of this long fibre bulk are required for a good board stiff- individual plies of the base board. The pulp, such as a high CSF freeness, the ness. Two to three top coats are usually type and intensity of fibre treatment of high E-modulus and the resulting high applied. The production of such a board the raw materials used, for instance by bending stiffness. In connection with a is connected with high investment costs refining, dispersion or by washing also double coating on the top side of the due to the sophisticated overall system help to optimize the base board quality. sheet, the requirements of surface prop- and paper machine configuration. The Finally, the basic processes of each erties and cleanliness can be fulfilled with economy in production is here decisively individual paper machine influence prop- a simple paper machine concept. Rela- determined by the selection of low-cost erties such as sheet formation, fibre tively low investment costs are involved raw materials for all plies. orientation, sheet compaction and vis-à-vis relatively high fibre costs. surface quality. The characteristics of the finished board are additionally Especially in Europe and Asia, multi-ply Current virgin and recycled fibre specified by surface treatment process- sheet forming concepts are used to pro- potential es such as sizing, coating colour appli- duce folding boxboard on the basis of cation and calendering. virgin fibres or secondary fibres (white How can the development of bending lined chipboard). The specific stock stiffness of the total base board be con- requirements with multi-ply board vary trolled by the characteristics of the filler For illustrating different board production depending on the ply; for the concept material? The technological comparison strategies, Fig. 1 compares the classic shown, a distinction between topliner, can be limited to the presentation of free- single-ply sheet forming concept with underliner, filler and backliner is made. ness, bulk (specific volume) and elastici- multi-ply sheet formation on a four-ply Simply speaking, for the two outer plies ty modulus (E-modulus) in order to eval- board machine. special surface and strength properties uate the possible suitability of the three are required, which can be achieved with mean fibre stock groups mechanical Solid bleached board – typical for pro- bleached hardwood pulp or high-quality pulp, chemical pulp and secondary fibre duction in the USA – consists of a single deinking grades. The underliner prevents grades. Fiber Systems 17

Fig. 1: Example for baseboard forming concepts.

Fig. 2: Bulk versus freeness.

Fig. 3: Elasticity modulus versus freeness. hardwood pulp Fig. 4: Stiffness index for comparison of softwood pulp filler stock. deinked pulp (ONP, OMG) E • v3 rec. supermarket paper, household collection Stiffness index = 1000 TMP E = elasticity modulus [N/mm2] SGW, RMP v = bulk [cm3/g] CTMP

The bending stiffness of a single-ply pa- 2 per sheet is experimentally established in 3,0 practice with a two-point bending stiff- /g] ness tester by bending a clamped paper 3 strip in the elastic range (DIN standard). 2,0 The established bending moment usually Bulk [cm agrees well with the mathematically established bending stiffness (S), which is the arithmetical product of the E-modulus 1,0 (E) and the third power of the caliber (d) of a single-ply material divided by 12. If the bending stiffness of multi-ply boards is calculated, the Steiner formula is used. 0

Bending stiffness: S = E • d3 /12 [mNm] 3

In Fig. 2, the bulk of different fibre stocks is plotted against freeness (all following 5000 data is taken from Voith Paper’s data ] base). The freeness serves as an auxiliary 2 4000 quantity to describe type and pre-treatment of the fibre stock. The areas marked 3000 in colour of the mechanical pulp types TMP, SGW and RMP cover a wide range 2000 of freeness with a high bulk of up to E-modulus [N/mm 2.5 cm3/g. The bulk range will of course 1000 be extended downwards by refining. CTMP is probably the most versatile fibre 0 stock, the properties of which can be var- ied by changing the process conditions, 4 22 such as chemical chip impregnation and )] the intensity of refining. With high specif- 2

g 20 ic refining work, i.e. with decreasing free- 2 /(s 8

ness, the high bulk level decreases. Hard- m 18 12 wood and softwood pulps with excellent - strength properties only have a low bulk, 16 which decreases further with more intensive refining. Secondary fibres, which 14 originally always consisted of a mixture 12 of wood-containing and wood-free recov- Stiffness index [10 ered papers, usually show mean specific 10 [SR] volumes from 1.3 to 1.8 cm3/g. Deinking 10 20 30 40 50 60 70 80 90 Freeness grades from newspapers and magazines 843 595 425 305 217 143 76 27 23 [CSF] 18

Fig. 5: Basic data for technological comparison of folding boxboard – White lined chipboard.

5 sible even today for so different sheet Folding boxboard White lined chipboard forming concepts and their especially tailor-made fibre recipes to co-exist in the Bending stiffness mNm 70 70 Board board sector. Basis weight g/m2 300 390

Fibre material Bleached softwood pulp White shavings Folding boxboard versus Bulk cm3/g 1.4 1.6 Topliner white lined chipboard Elasticity modulus N/mm2 5500 3500

Basis weight g/m2 60 60 Why it was even possible for secondary fibres of a quite different type to substi- Fibre material Groundwood Household collection tute primary fibres in board manufactur- 3 Bulk cm /g 2.2 1.7 ing. An economical advantage is the low Filler Elasticity modulus N/mm2 1500 2500 production costs of secondary fibres due to low waste paper prices and compara- Basis weight g/m2 180 270 tively low energy inputs for their prepara- Fibre material Bleached softwood pulp DIP tion. Recycled stocks of analoguous pri- 3 Back- Bulk cm /g 1.4 1.6 mary fibres rank technologically only a liner little behind (for example when compar- Elasticity modulus N/mm2 5500 3000 ing market pulp and hardwood pulp). Basis weight g/m2 60 60 An interesting technological and econom- and a prepared mixture of supermarket other strength properties in comparison ical comparison offers the comparison waste and household collections are with mechanical pulp. with the board grades of folding box- shown here as an example. board on virgin fibre basis and white The actual stiffness potential of fibres lined chipboard on secondary fibre basis An almost contrary picture is obtained used as a filler material referred to in this (Fig. 5). The reference value defined here from plotting the E-modulus against free- paper can be determined with a stiffness is the bending stiffness, which is also ness in Fig. 3. With increased refining, index (Fig. 4). The chosen stiffness index used as one of the most important sales chemically pulped fibres show an impres- depends on the bending stiffness calcula- factors. It is specified as 70 mNm. sive increase in fibre bondage capability, tion and is independent of the basis which leads to high strength values at weight. The application of the stiffness Here, folding boxboard consists of three low elongation, i.e. to a high E-modulus index is limited to the filler ply or single- virgin fibre plies. The topliner consists of of 5000 N/mm2 and more, with softwood ply paper sheet. 60 g/m2 bleached softwood pulp, the filler pulps showing higher values due to their of 180 g/m2 mechanical pulp and the higher long fibre content. In comparison, It is noticed that in particular softwood backliner again of 60 g/m2 softwood the mechanically pulped fibres show an pulps can have the highest bending stiff- pulp. The basis weight of the folding extremely poor result with low E-modulus ness values, although their bulk is com- boxboard is thus 300 g/m2. values. The great advantage of secondary paratively low. The bending stiffness of fibres becomes evident here. They cannot single-ply papers from mechanical pulps In order to achieve a comparable stiff- only be produced at a more favourable is extremely low. Secondary fibre stocks ness level for a three-ply white lined price, but often have technological ad- cover a wide spectrum in the centre-field. chipboard with recovered fibres, the fol- vantages concerning the E-modulus and This diagram clearly shows why it is pos- lowing model set-up can be used. In the Fiber Systems 19

Fig. 6: Total board stiffness – Influence on bulk and elasticity modulus of the filler.

Fig. 7: Total board stiffness – Optimization of the filler ply through remixing. topliner, pulp is replaced by prepared 6 white shavings of a high brightness. The 130 130 most favourable raw material, i.e. house- 120 120 hold collection, is chosen for the filler 110 110 ply. Deinking stock is used in the back- 100 100 liner. The assigned stiffness-relevant 90 90 characteristics are given in Fig. 5. The 80 basis weights for topliner and backliner 80 remained to be 60 g/m2. The model cal- Bending stiffness [mNm] 70 70 1,6 1,8 2,0 2,2 2,4 1000 2000 3000 4000 5000 6000 culation for board stiffness shows that Bulk [cm3/g] E-modulus [N/mm2] the basis weight of the filler had to be in- Furnish Basis weight g/m2 creased by 90 g/m2 to 270 g/m2 in order White lined chipboard 390 g/m2 Topliner White shavings 60 to reach the stiffness value of the virgin Initial board stiffness 70 mNm Filler Household collection 270 Backliner 60 fibre board. The increased basis weight DIP of the white lined chipboard with cost- 7 wise much more favourable fibre components reduces the cost advantage of the E-modulus Bulk 100 N/mm2 cm3/g recycled board. In fact, the costs for a SGW White ton of finished stock (bone dry) for the Top 3500 1.6 CTMP shavings white lined chipboard mentioned are only 90 Household 2500 1.7 half the costs for folding boxboard. TMP collection SGW 1500 2.2 A major reason for the increased material 80 Filler TMP 1800 2.1 weight of the white lined chipboard is to be found in the significantly low bulk of CTMP 2000 2.1 Total board stiffness [mNm] Total 70 the prepared household collection com- Household collection Back DIP 3000 1.6 pared to the mechanical pulp integrated 0 20 40 60 80 100 in the virgin fibre board. Mixing ratio [%]

By which measures can the technological Based on the experience that all mechani- ages of SGW, TMP or CTMP up to a mix- properties of the filler stock, which are so cally produced fibres such as TMP, RMP, ing percentage of 100 % are added to the relevant for board stiffness, be im- SGW and CTMP are destined for this ap- household collection, decisively higher proved? Fig. 6 shows the ideal properties plication, Fig. 7 shows the possibility of board stiffness values will be the result. that the filler should have. The increase loosening the compact fibre structure of This method is used in some board mills, in board stiffness, on the one hand by in- the prepared household collection by and no significant technological differ- creasing the specific volume of a ficti- adding mechanical pulp to increase the ences can be observed for the three eval- tious filler stock and on the other hand, volume of the filler ply mixture. The aim uated mechanical wood pulps. by increasing the E-modulus in the filler, is to increase the bending stiffness of the is shown in two diagrams. It becomes ev- previously defined white lined chipboard. Fig. 8 shows the cost side of such a filler ident that for this board model, volumi- The starting point (grey point on the left ply optimization. The raw material costs nous fibres for the filler ply are given of the diagram) is the board model white for the entire three-ply board described clear preference to a fibre material with lined chipboard with approx. 70 mNm to- are presented based on the average mar- high E-modulus. tal board stiffness. If increasing percent- ket prices of the year 2000. Adding the 20

Fig. 8: Total board stiffness – Furnish costs for optimizing the filler ply through remixing.

Fig. 9: Influence of machine type on bulk increase of recovered fibres.

8 9 450 20 € /t] White lined chipboard Furnish costs /t

€ CTMP 400 15 White shavings 460 Kneading Disperger 350 Household collection 155 10 TMP SGW 245 300 5 SGW TMP 320 Disk Disperger 250 Rel. change in bulk [%] CTMP 460 0 Furnish costs of total board [ Household collection 260 200 DIP (ONP, OMG) -5 020 40 60 80 100 0 50 100 150 200 Mixing ratio [%] Spec. dispersion energy [kWh/t]

most expensive filler stock CTMP will re- due to fibre curling. However, this is also Conclusions sult in highest finished stock costs for accompanied by partially undesirable ef- The wide variety of board structuring al- the base board. In this example, the tech- fects such as higher wet web stretch and lows free choice of fibres, either virgin or nological/economical optimum is found shrinkage, higher porosity and adsorp- recovered. The fibre material has to be by adding low-cost SGW or RMP. There- tion capacity, lower static strength values selected according to the individual ply fore, these mechanical pulps are widely and lower dewatering resistance. requirements! Bulky fibre stock should used as filler material or as addition in be used for the filler ply to increase the multi-ply board production. The two types of Voith dispergers, (high- total board stiffness. speed disk disperger HTD and low-speed kneading disperger KD) may cause fibre The lower stiffness potential of house- Processes for enhancement curling, in spite of different operating hold collection used in the filler ply of of bending stiffness principles (Fig. 9). The volume and poros- white lined chipboard must be compen- ity increase after the kneading disperger sated by higher grammage and/or remix- In addition to the raw material selection, is considerably higher. ing with mechanical pulp. Of course, the an appropriate process technology repre- furnish costs for white lined chipboard sents a further tool to develop specific fi- Fibres also show a different tendency for from recovered fibres are significantly bre properties and to optimize the board fibre curling in the kneading disperger. lower than for folding boxboard from vir- product. Refining with proper stock-spe- Various examinations also revealed that gin fibres. cific refining parameters may lead to a wood-containing stock shows a high per- desirable strength increase, such as the centage of reversible curling (latency be- RMP/SGW are most suitable for the filler increase in plybond and the increase of haviour), whereas curling of wood-free fi- stock. The kneading disperger helps to the E-modulus. It is, however, connected bres is irreversible to a great extent. increase bulk where fibres show a ten- with a reduction in bulk of all fibre types. Therefore, the effectiveness of the knead- dency to curl. The decrease in air permeability is more ing process cannot be generally predict- dramatic, which is of importance for cer- ed. Pilot plant trials carried out with the tain board grades, such as for instance kneading disperger for an individual raw gypsum board. With secondary fibres, material offer the board manufacturer a Presented on the Voith Paper Customer Conference dispersion processes can influence bulk possible alternative. “ahead 2001, Vienna, May 8-10, 2001. Paper Machines 21

Multi-Layer and Multi-Ply Concepts – Driving forces and advantages

The discussion of multi-ply/multi-layer in order to reduce the total cost per net concepts is as old as the paper industry ton. But this will also reduce the quality itself. Though the limitations of modern level. wet part concepts are quite different from those of the past, the basic princi- In addition, the general furnish trend has ples are still valid. In order to minimize to be considered and may change the cy- the total cost per net ton of paper, pro- cle time until the market quality level is duction and high fibre yield have been reached. At this point at the latest, the the main driving forces for the develop- question will come up how to speed up The author: ment of advanced forming concepts. the machine further and simultaneously Dr. Günter Halmschlager, This paper focuses on the reasons for maintain the quality level. Paper Machines Board and Packaging multi-ply/multi-layer technology from the past until today and introduces a In case the machine production is limited new multi-ply/multi-layer concept which due to the wet part, there are mainly two offers additional advantages. options: add one more ply or switch to the next forming generation.

Multi-ply cylinder mould formers Paper quality and production In cylinder machines, multi-ply forming When installing a new paper machine, the was required because of the very limited layout has to be done in a way that the production of one single former. The market quality demands can be fulfilled operating window of a recent cylinder very soon after start-up (Fig. 1). After op- mould former is shown in Fig. 2. timization, a new paper machine normally exceeds the quality demands, enabling Production can be increased by adding the papermakers to increase production additional plies, as long as the operating

Original machine layout

Furnish

Quality Market demand

Machine speed Fig. 1: Effects of machine “squeezing”. 22

Fig. 2: Basis weight pick-up of a cylinder mould machine.

Fig. 3: Forming concepts – Design limits for board machines.

Fig. 4: Forming concepts – Design limits for packaging paper machines.

2 speed is not a limiting factor. To over- 800 8-plies come the speed limitation, an upgrade to the next forming generation is required. 600 )

2 However, such concepts still reach rea- sonable production levels for board 400 grades. 4 8

200 basis weight (g/m Forming concepts – design limits for board grades 1-ply 0 100 200 300 400 Multi-ply fourdriniers combine the advan- speed (m/min) tages of single fourdriniers with those of multi-ply cylinder mould formers. As 3 shown in Fig. 3, the operating window of 900 multi-ply fourdriniers is much wider compared to the cylinder mould formers. 700 ) 2 The driving forces for multi-ply fourdriniers for the production of board have 500 been speed, which means production, and sheet quality such as smooth formation and bending stiffness. basis weight (g/m 300

100 Forming concepts – 35 300 800 speed (m/min) design limits for packaging grades

4 The trend towards lower basis weights 600 and, at the same time, high production levels made gap formers the state-of-the- 500 art concept for packaging grades for new

) machines and rebuilds. Similarly to the 2 400 cylinder mould formers discussed before, 300 it is again the speed limit – in this case of the fourdriniers – which is the main dri- secondary fibre 200 fresh fibre secondary fibre ving force for the next forming genera-

basis weight (g/m tion. 100 Voith Paper introduced the gap former 0 500 1000 1500 2000 technology as early as in 1992. In the speed (m/min) meantime, 14 gap formers for board and Paper Machines 23

Fig. 5: Effect of multi-ply gapforming on strength.

Fig. 6: Single-ply sheet 200 g/m2 (top). Double-ply sheet 200 g/m2 (bottom).

5 6 250

200

150

100

1 former 2 formers

tensile strength MD [N] 50

0 100 150 200 250 300 basis weight [g/m2]

packaging grades are in operation, in- Fig.4 further shows operating points (dark The crosscuts as shown in Fig. 6 demon- cluding the very first double gap former blue) of Voith paper machines already in- strate the higher density in the centre of machine worldwide. One further top ply stalled as well as layout points of recent a multi-ply gapformer sheet. gap former is being delivered right now. projects (light blue). A multi-ply gapformer concept (Fig. 7) These gap former types have been spe- Apart from production, there are other ensures best formation and strength at cially developed for multi-ply board and reasons which make a multi-ply gapform- highest production levels. packaging papers. The high two-side ing concept attractive. drainage capacity of the DuoFormer™ Base and DuoFormer™ Top results in Strength is one of the decisive factors for Multi-ply/multi-layer technology very good sheets, even at highest pro- the production of linerboard. There is a duction levels. significant improvement in strength when In the following, a new concept using producing two plies instead of one ply. three secondary fibre fractions will be in- Fig. 4 compares the operating windows Though the strength might be different troduced. If the multi-ply sheet is addi- of multi-ply fourdriniers (blue area) with when using different forming concepts, tionally stratified in the headbox, further a single-ply gap former and a double-ply the multi-ply technology always gives a advantages for even better machine per- gap former. It can be seen that single-ply clear advantage. formance can be achieved. gap formers (red graph) are very compet- itive in the medium speed range. A sheet Fig. 5 shows the breaking length of a In such a concept, the stock is fractionat- with 150 g/m2 can be produced at a 100% OCC sheet for different basis ed as follows: speed of eg. 950 m/min with one gap- weights, using one or two gap formers. It long fibre former only. Nevertheless, for very high can be seen that the two-ply concept re- long/short fibre production, a second ply is required. sults in a clearly better strength at higher short fibre. basis weights. Sheet forming is enhanced The yellow graph shows the operating with better formation and lower z-orienta- The long fibre fraction is fed to the Duo- range for a two-ply gapforming concept. tion of the fibres, which will both help to Former™ Base, which produces the top Such a concept allows to produce a high optimally utilize the fibre potential, thus ply. The long/short fibre fraction and grammage sheet even at high speeds. saving fibre cost. the short fibre fraction are supplied to a 24

Fig. 7: Multi-ply/multi-layer gapforming concept.

7 MasterJet™ G DuoFormer™ Base MasterJet™ M2 DuoFormer™ Top

multi-layer headbox in a DuoFormer™ fibre sheet is more open and easier to low content of stickies. Therefore, the Top, thus allowing additional sheet strati- drain compared to a short fibre sheet. contamination of the fabrics will be re- fication. duced, which is again a plus for runnabil- Since the long fibre fraction and the ity but also for cleanliness and mainte- Fig. 8 shows the location of the fractions long/short fibre fraction are located on nance. during the drainage process. The long/ the outer sides of the sheet, the water short fibre fraction is drained through the can drain with less resistance. This helps The higher surface porosity of a stratified outer wire. The short fibre fraction con- to avoid sheet crushing in the press sec- sheet allows the steam to escape easier, taining most of the fines is drained tion, which is especially important for which is the third advantage. Due to the through the inner wire. Gentle drainage high production. Better drainage also in- fact that the sheet gets more open to- by the forming roll helps to keep the creases wet densification, which is posi- wards both surfaces, also the danger of fines of the short fibre fraction in the tive for the strength development. blistering and delamination is reduced. sheet, which is desired for several reasons but especially for good plybond. The long/short fibre fraction on the outer Effects in the dryer section Effects in the size press/SpeedSizer™ wire helps to reduce washout effects. In the dryer section, there are also advan- High strength figures demand full starch The sheet leaving the forming section has tages related to the multi-ply/multi-layer penetration. At high speeds, the dwell been stratified as follows (Fig. 9): technology (Fig. 11). time in the nip gets shorter and it is more difficult to achieve full starch penetration long-fibre top ply on the base wire With such a concept, the long fibre frac- of the sheet. short fibre fraction with high fines tion is facing the dryer cans. Due to bet- content inside the sheet ter bonding of the longer fibres in the In the press section, the stratified sheet long/short fibre fraction as back ply on sheet, the dust development in the dryer structure makes drainage easier. Vice top side. section will be reduced. Less dust will re- versa, the open surface of the stratified sult in enhanced runnability and im- sheet allows better starch penetration proved converting properties. (Fig. 12). Effects on the press work The second advantage is that the long/ Especially for high basis weights and Figure 10 shows a schematic sketch of short fibre fraction is facing the dryer high production, this effect is of advan- a press nip. As generally known, a long fabric. This fraction is very clean with a tage. Paper Machines 25

Fig. 8: Two-layer gapforming. Fig. 11: Effects of a stratified sheet in the Reduction of washout effect pre-dryer section. – higher retention. The long fibre fraction faces the dryer can surface – reduced dusting; Fig. 9: Sheet structure after couching. The clean short/long fibre fraction faces the dryer Perfect location of fines fabric – improved runnability due to low stickies – higher ply bond. content.

Fig. 10: Effects of a stratified sheet on the Fig. 12: Effects of a stratified sheet in the press work. size press/SpeedSizer™. More open sheet surface Higher porosity on outer sides – better drainage – better starch penetration (CMT, SCT) – high wet densification. – better ply bond in the centre.

8 9 10 long long/short long long/short

short short

felt

long/ l/s short l/s s s l short long

felt

11 12 porosity

dryer fabric

Effects on converting Summary quence, the natural resources are utilized more efficiently, which helps to protect The long fibre fraction on the surface The main driving forces for the multi- our environment, but also the total costs maintains a certain roughness required to ply/multi-layer technology have been per net ton of paper can be reduced, thus achieve the desired sliding angle. Further, speed and production, but also quality. increasing profits. the hot glueing properties will improve. This also applies to the latest board and The glue can better penetrate into the packaging gapforming concepts. surface and develop a mechanical inter- lock with the sheet. Though the additional advantages of a stratified sheet are difficult to quantify, this technology will improve the machine performance and runnability as well as the sheet properties required for further Presented on the Voith Paper Customer converting and final usage. As a conse- Conference “ahead 2001, Vienna, May 8-10, 2001. 26

One Platform Concept

For years, the paper industry has Gratkorn 11 (Triple Star) was designed in systematic development, the One Platform generated a steady stream of numerous 1997for an annual production of 470,000 t Concept. innovations. According to surveys, and is, therefore, still the highest-capacity Voith Paper is the most innovative paper fine paper machine in the world. The demands mentioned above cannot be machine manufacturer in the world. met simply by building faster and more There is no end to the creativity and With Dagang PM 1 and PM 2 in China, complex paper machines. These demands drive at Voith Paper – there are plenty 1998 saw the delivery of the widest paper can only be met if the paper manufactur- of ideas – but “Innovation takes machines in the world, with a wire width ing process is analyzed in context and methodology”. of 10.5 m. comprehensive solutions are developed. The following examples show how com- These three global references document plex the interrelationships are. History the state-of-the-art in the years 1996 to 1998. It is clear how new developments Voith Paper had already been building were introduced piece by piece. Two Examples of Challenges large, fast and productive paper machines in the past. 1. Example: Use of Recovered Paper Challenge for Recycling Braviken PM 53 (1996 series) was the first paper machine in the world that Paper manufacturing is a complex Voith Paper can, without reservation, be could exceed 1,800 m/min – thanks to process, which must continuously meet called a leader in secondary fiber prepa- the shoe press. new demands. In many regions of the ration. Voith Paper has a long history of world, the increased use of secondary experience in the design and outfitting of fibers is required; while on the other secondary fiber preparation facilities hand, it is clear that the quality of recov- (dispersion, flotation and sorting), but ered paper for recycling is decreasing. who decides how the finished prepared The paper types are also undergoing con- stock must look? stant change. How many dirt specks are permissible? In order to reduce costs, ever-increasing How much ash is needed? amounts of filler are used and, at the How is the calenderability? same time, the basis weight is diminish- How suitable is it for coating? ing. Ever-higher yields and faster produc- Or, is this the maximum yield? tion are expected using ever-decreasing amounts of fiber. The fact that quality de- All of these questions can only be an- mands are simultaneously increasing is swered in the overall context of the man- not surprising. This all creates enormous ufacturing process and the end quality The author: Bernhard Kohl, pressure to innovate, which can only requirements. This is precisely where the Paper Machines Graphic be successfully responded to through a One Platform Concept begins. Paper Machines 27

Fig. 1: Challenges to the One Platform Concept.

Fig. 2: Extent of the One Platform Concept.

2. Example: Base Paper Requirements 1

A second example says: “In order to pro- Raw material Paper Machine Paper product duce standard LWC paper, which is film- coated and calendered online, what condition does the base paper have to be Recycled fibres Productivity Bulk/gloss in?” It is not enough to define values Quality of such as breaking length, smoothness, Online process Filler content oil absorption or porosity. The entire waste paper process must be reanalyzed. Stock prepa- Speed Basis weight ration, post refining and base paper production have to be viewed in context and Increased innovation pressure leads to One Platform Concept occasionally must also be tested. The result, however, can only be evaluated in paper which has been coated, calendered 2 and printed. Investment and production costs Process The fundamental principle of the One Platform Concept is to view the individual Technology steps in context. Automation

Paper product and Raw material Paper machine printing process The Three Basic Rules Clothing

One platform for all graphic paper Roll covers grades Service In order to permit a comprehensive development for a broad application field, Continuous paper product development there must be only one platform. Definition 4. Optimization of the process Specific modules for the specific 5. All paper-influencing surfaces paper grades The One Platform Concept means the (clothing, coatings) In order to cover the specific require- comprehensive solution of the stated 6. And comprehensive service concepts. ments of individual paper grades, there goal – the production of paper. are uniform quality modules that are What is special about this challenge is built into this platform: This includes: the dynamics of the stated goal. De- 1. Paper Contact Systems (clothing, mands from the raw materials, market roll covers, special machine elements) 1. A paper machine with all of the steps producers and financial markets lead to 2. Process Control (from stock preparation to finishing) ever changing peripheral conditions, 2. Automation of the entire facility which must be considered at each start Suitable for all raw materials 3. Paper technology know-how for a solution. The One Platform Concept must be suitable for all available raw materials. 28

This is what new paper machines look like! The persistent implementation of experience with the One Platform Concept puts Voith Paper in a position to offer optimal paper machines for any desired type of paper.

Advantages Newsprint DuoFormer TQv Tandem NipcoFlex Based on the above-mentioned elements, If all paper machines are built in accor- ModuleJet™, DuoFormer™ TQv, TopDuo- dance with the One Platform Concept, a Run, EcoSoft™ and Sirius™, the Tandem- maximum of experience assures a mini- NipcoFlex™ offers an additional degree of mum of risk. This experience, from all of freedom. For very light paper grades (un- the One Platform Concepts, is immediate- der 40 g/m2), a smooth transfer belt has ly available to all. advantages over felt, whereas the asym- metry in the surface can be compensated Operating experience from existing facili- for in the calender. ties can be used to further optimize individual components and developments. Ex- Magazine Papers (SC) DuoFormer TQv Tandem NipcoFlex perience from new facilities can be used A Janus™ must be used as a quality mod- to increase the capacity of existing facili- ule. Because of the high demands with ties that were placed in service earlier. regard to symmetry, the TandemNipco- Flex™ press must be equipped with four At the same time, this accumulated expe- felts. All other elements were already part rience leads to improved production facil- of the newsprint concept. ities with faster start-ups and higher production.

As a whole, the One Platform Concept LWC Papers DuoFormer TQv Tandem NipcoFlex improves economy and simultaneously The quality module SpeedCoater™ is inte- minimizes risks in all investments. grated for online coating. At the same time, this includes the pre-calendering and the end drying by a ModuleDryer™. The Proven Concept The other elements were transferred from the magazine paper concept. With all of this experience in several facilities for a wide variety of graphic papers, Voith Paper is in a position to offer a proven One Platform Concept. Office Papers DuoFormer TQv Tandem NipcoFlex This cumulative experience was the basis These papers are likewise surface-treated for the trust that convinced SCA Laakir- by the SpeedCoater™, but pre-calender- chen and Myllykoski to each order a new ing is not required. On the other hand, paper machine using the One Platform curl in cutsize papers needs special con- Concept from Voith Paper. sideration. Therefore a CombiDuoRun is used. The remaining elements correspond to the basic newsprint concept. 29

TopDuoRun Ecosoft Sirius

TopDuoRun Janus MK 2 Sirius

TopDuoRun Calender SpeedCoater ModuleDryer Janus MK 2 Sirius

TopDuoRun SpeedCoater CombiDuoRun Ecosoft Sirius 30

Why One Platform Concept?

Could you please give a short outline of basic concept, this is achieved by devel- the One Platform Concept? oping the systems in contact with paper (fabrics, belts, roll covers and special During the last 5 years, Voith Paper has machine elements) and the process con- developed a completely new paper ma- trol with regard to the individual require- chinery concept for graphic grades. No ments. This means that the One Platform aspect of the paper machinery process Concept is a tailor-made solution which was left out. We have launched a new type takes the local requirements and the cus- of production process onto the market. tomer’s production layout into consideration –like a tailor-made suit. In this connection, we have tried to com- A discussion with Dr. Hans-Peter bine all the different concepts that exist- Sollinger, Voith Paper, on the ed for the different paper grades into an What are the goals? backgrounds, strategic targets and optimal and modular basic concept customer benefits regarding the applicable to all papers. We call this The One Platform Concept by Voith Paper modular One Platform Concept. modular basic concept the One Platform is more than a development and design Concept. concept. On the contrary, it is our company philosophy which resulted from the challenges given by the market. It is the Why has it been developed? key that allows us to reach our company targets and to fully meet the require- The reasons for the development of the ments and wishes of our customers. One Platform Concept were the increased demands being made on the entire paper With the One Platform Concept, we have production process from the fibre to the developed a forward-looking, modern finished paper. Due to the increased use concept on which we would like to estab- of recovered paper for the reduction of lish all further steps in the years to come. raw material costs with a simultaneous We feel that sticking to this basic concept deterioration in the quality of recovered is of great importance when we consider paper, new processes had to be devel- risk management. It provides our cus- oped. The trend towards online process- tomers and us with the necessary secu- es for the paper production made consid- rity. erable investment cost savings possible. Fast, reliable and optimal start-ups, safe- Simultaneously, the demands on the end guarded with regard to quality and relia- product have increased and this meant bility, are the benefits that we see in the that we had to give intensive thought to One Platform Concept. the end product and the printing process. In particular, we had to consider the dif- Our customers should already be able to ferent quality requirements of the graphic produce profitably during the start-up grades from newsprint and SC qualities phase. Despite the image gain, we want to coated woodfree and wood-containing to make projects clearly and persistently papers. While maintaining the modular more profitable with first-class projects Paper Machines 31

and by a reduction in the project handling With all the experiences gained from vari- some innovative and very interesting costs. This is an advantage which pays ous plants for different graphic grades, concept solutions. But some time will off directly for the purchaser and for us Voith Paper is able to offer a proven One pass until we have developed them to as well. Platform Concept. market maturity and will be able to integrate them into the current One Platform Concept. When did you introduce the What was the response by the market? One Platform Concept? But above all, we see our future tasks in We were really surprised by the indus- the further optimisation of the existing It is not possible to state a definite date try’s great interest in our One Platform One Platform Concept. There is still a for its introduction, it was introduced Concept. The combination – most mod- considerable potential in the optimisation step by step. On the basis of our world ern concept and highest possible relia- and further development of process con- references between 1994 and 1998 such bility – is of great concern to the paper trol and the systems in contact with pa- as Braviken, Triple Star and Dagang, for industry. In this industry, risk awareness per, i.e. forming fabrics, pressing fabrics example, we introduced this concept in has started to change considerably. and drying fabrics, as well as belts and different stages. Today, we speak of three roll covers. The interplay between ma- stages: With the One Platform Concept, we fully chine, systems in contact with the paper Basic Concept 1998 - 1999 met the spirit of the times in the industry. and process control has a considerable Advanced Concept 1999 - 2000 influence on productivity and product Consolidated Concept from 2001. Concerning this concept, our sales de- quality. partment receives many words of encour- agement from all sides of the paper in- This is a continuous optimisation process Have you already been able to use this dustry. Races for daily records such as which we implement in close co-opera- concept successfully? If so where? speed (peak results) no longer count. tion with our customers on their operat- Nowadays, “quality tons on the reel” are ing production units and on Voith Paper’s Yes! With the “Basic” phase plants, e.g. important, throughout the year. Quota- pilot units, where we are supported by Eltmann, we were already able to imple- tions of our customers underline this, for the experts from Voith Paper and Voith ment the best production start-up curve example the one by a Finnish customer: Fabrics. for newsprint. “The production-oriented pulp and paper industry competed for the most beautiful, Process optimisation plays an important Likewise, with the plants of the “Ad- largest and fastest paper machine. Some- role with Voith as the preferred process vanced” phase such as Schongau, for ex- where in the speed range towards and supplier. ample, where it was possible to attain the above 2,000 m/min, the target to produce highest specific production values of all not only more paper but also to increase Voith offers the best prerequisites for comparable magazine paper units during profits was forgotten. This has to change this: the first 6 months. fundamentally.” Voith is the only supplier who produces In the case of Perlen, for example, (“Ad- all systems of a paper machine that are vanced” phase) we were able to produce What can be expected in the future? in contact with the paper and offers the high-quality, online coated and calen- precondition to systematically implement dered magazine paper right from the be- We will further develop the basic concept process optimisation with the One Plat- ginning, although Perlen had not had any for the One Platform Concept. At the mo- form Concept. experience with coated paper before. ment, we are dealing very intensively with 32

Innovative Paper Machine Design

Design is not everything, but without It almost goes without saying, therefore, pearance? So is there any further need design, everything is nothing! that the special qualities of innovative for aesthetic design? Maybe this would As demonstrated by aircraft and auto- products should be underlined by their merely comprise expensive cosmetics? mobile design ever since streamlining outward appearance. It is because of considerations like this, was discovered, elegance and efficien- that plant development engineers have cy go hand in hand. And it is equally An exception to this rule has been (and perhaps waited longer than others before true that well-designed ergonomic still is to some extent) large installations integrating aesthetic design concepts into products sell better – as initiated by in the capital goods and machine building their complex projects. the legendary “Bauhaus” designers industries. Since their design focuses ex- and architects. clusively on the best possible cost/bene- Those times are definitely over, however! fit ratio, surely such perfection should These days progressive manufacturers, speak for itself in terms of outward ap- also in the paper industry, no longer re- Paper Machines 33

The illustrations show artist’s impressions and computer simulations of the new Voith Paper machine design as first implemented on PM 9 at Haindl Paper. gard good architecture in new plants or re- value-added, enhanced work safety and design. Paper machine design studies builds merely as a space and cost saving ergonomy, better handling and mainte- have been also assigned both en bloc and advantage. They deliberately employ good nance. It furthermore brings material and in part to leading universities and techni- aesthetic design as a marketing tool for cost savings wherever possible, both in cal institutions. enhancing their corporate image. And this plant construction and installation. Eco- applies inside the mill as well as outside. logical aspects such as energy and re- Since the introduction of our “One Plat- source conservation also play a growing form Concept” of modular system com- How can good design be defined? At any role in good design these days. ponents on an interlinking basis, all our rate, it has nothing to do with superficial designs are now checked for perfect inte- cosmetics or fashion. Based on thor- For some time now the basic develop- gration of all modules. In this connection oughly systematic aesthetics, it also in- ment team at Voith Paper has been as- the opportunity arose to integrate such a corporates greater product benefit and sessing important innovations for optimal new and comprehensive design – for innovation has to be systematic!

Prof. Horst Diener and his colleagues Dipl. Ing. Peter Koloch and Dipl. Ing. (FH) Reinhard Frank of Designpraxis Diener in Ulm partnered us with their competence 34

and experience in reaching this ambitious The team’s first task was to integrate the goal. Thanks to intensive dialogue be- optical design of a typical Voith Paper tween the Voith Paper development engi- production line. In view of the plant size neers, the corporate marketing people and complexity, an overall design con- and the independent design team, all cept was first worked out and its imple- tasks and implementation phases crys- mentation divided into short, medium tallized step by step out of the detailed and long-term measures. situation analysis. One of the first measures taken was on Visualize quality – comprehensively and the walkways, which greatly affect the homogeneously! This summarizes the overall appearance of the paper machine. goal of the last few months’ work. Al- though all the individual sections of a Together with the machine designers the Voith Paper machine such as the former, walkway system at the former and press press and dryer sections and reel section sections was therefore revised, and divid- work together outstandingly well, the ed into two levels or “storeys” as far as visual impact of each component has so possible. The stairways at the former far been treated relatively individually. were integrated into a kind of staircase. 35

The result of this work is not only a more Since the former and press sections get developed which fits various machine orderly impression, but also easier ac- very dirty during operation, the personnel layouts. cess for operation and maintenance. The have to spend a lot of time cleaning up to walkways were fitted with panels, which ensure efficiency and safety. This work Whether walkway panels, exhaust hoods, serve several purposes: will be reduced in future thanks to large splash guards or partitions – all these de- splash guards. These not only keep off sign elements fit well together both opti- They prevent dazzling by the lighting in- the dirt, but also reduce noise. For wire cally and dimensionally. Overall, they stallations, while also improving the ca- and roll changing, the guards can easily form the new image of Voith Paper ma- ble run and access. As a welcome side be moved or swung away like doors. To- chinery and are a protected part of the effect, these panels provide enough sur- gether with the walkways, they also serve Voith corporate design. face area for clearly labelling each system for optically harmonizing the machinery component. complex. Step by step the new Voith Paper design is being implemented. After its success- Based on Voith corporate blue, the walk- The splash guards on the former and ful premiere on PM 9 at Haindl Paper, the ways optically link the modular elements press section are similarly installed in the design team is working on further ma- of the One Platform concept into a har- reel section, but for protection purposes. chine concepts and going into greater monious whole. In this connection a new modular cladding depth with regard to operational, mainte- and support element system has been nance and rationalization benefits. 36

Soporcel PM 2 inauguration ceremony

On October 18, 2000 Soporcel’s new October 18 is a particularly important PM 2 production line was officially date for Soporcel: on that date in 1984 handed over in the presence of political their new pulp mill was inaugurated – ac- and industrial leaders including cording to former President Antonio Dr. Jorge Sampaio, President of the Ramalho Eanes “Portugal’s most impor- Republic of Portugal, Minister of tant industrial project”. On October 18, Economy Mário Cristina Sousa, and 1991 their PM 1 went into operation. So State Secretary José Junqueiro. for Soporcel it is now a tradition to celebrate the company’s most important The author: events on October 18. They take it as a Dieter Babucke, good omen for ongoing expansion in the Paper Machines Graphic future. 37

President Sampaio congratulated the entrepreneurial vision and purposeful im- Technical data of PM 2, Soporcel management in his speech on plementation. built on the “One Platform Concept”: Wire width 9,350 mm the company's successful growth so far Web width 8,600 mm and this courageous new step into the Board Chairman Alvaro Barreto referred Overall paper machine length 182 m future, their strategy of cost-effectively afterwards to the special mission fol- Grades: wood-free graphic papers 2 implementing the PM 2 project in tune lowed by Soporcel: the goal already set from 60 to 110 g/m Annual output 400,000 t with Portuguese market capacities. Econ- in 1984 of integrating all production Production speed 1,500 m/min at 80 g/m2 omy Minister Sousa emphasized that the processes as comprehensively as possi- Design speed 1,700 m/min success and quality of Soporcel papers ble in the company’s environmental re- and the capacity expansion now attained sponsibility – ranging from sustainable with PM 2 should not be measured in forestry to the finished paper products. tonnes alone, but rather as the result of He pointed out that Soporcel is already 38

3 responsible for 55,000 hectares of forest measures. The company had attained a central and northern Europe. Our de- covering about 30 % of current raw ma- standard thereby which not only im- clared target is therefore not only to terials needs, furthermore that thanks to proves on the EU air pollution limits, but strengthen our presence in the traditional a model agricultural programme, more is also much lower than main internation- markets of Portugal, Spain, France and than one hundred thousand additional al benchmark levels. Italy, but also to expand beyond these hectares are being re-afforested in an markets. In terms of figures, we plan ideally eco-economical manner. For the 900 Soporcel employees, this over the next three years to increase our PM 2 inauguration was certainly a source market share in the European Union from In this connection the Board Chairman of pride and satisfaction. But it was also 7 to 11 % for office papers and from 6 to mentioned another notable company in- an important step toward breaking new 10 % for offset printing papers”, said vestment of exemplary character: over ground. “Our market expansion in the Alvaro Barreto. With 730,000 tonnes the last few years Soporcel had spent South European countries is notable, but annual output capacity, Soporcel is now about 100 million Euro on state-of-the-art due to lack of production capacities we Europe’s leading producer of office pa- clean-air technology and anti-pollution are only just starting to find our feet in pers. 39

In closing, the Board Chairman paid trib- During the year preceding this PM 2 in- Fig. 1: Dr. Jorge Sampaio, President of the ute to the PM 2 project team for their auguration, CEO Luis Deslandes was par- Republic of Portugal, giving his address at the Soporcel PM 2 inauguration. outstanding performance and excellent ticularly honoured by being appointed cooperation with Voith Paper. PM 2 had chairman for the next two years of the Fig. 2: Board Chairman Alvaro Barreto talking been implemented two months earlier FAO advisory committee for paper and about Soporcel's special mission. than planned, including a very modern, forestry products. Congratulations! This Fig. 3: Luis Deslandes, CEO Soporcel, gas-operated power plant with 67 MW unique committee, comprising members and Hans Müller, Voith Paper. output, thus improving significantly on from more than thirty countries on all the budgeted costs. continents, supports the head of the FAO Fig. 4: PM 2 reel section. in all matters concerning worldwide de- Fig. 5: Part of the stock preparation line. After reaching the final production speed mand for forestry and paper products, in- of 1,500 m/min at 80 g/m2 basis weight, cluding production aspects. Soporcel PM 2 will be the fastest and most efficient production line in the A detailed description of the Soporcel world for wood-free graphic papers made PM 2 project is given in twogether 8, of eucalyptus furnish. Decisively impor- pages 18-20. tant for the efficient planning and implementation of this project was the excellent cooperation of the Soporcel team, 5 under Chief Executive Officer Luis Des- landes, with the Voith Paper project team. Thanks to this partnerly teamwork and constructive dialogue at all times, even the most difficult problems in the critical deadline situation typical of such ambitious projects were solved to the complete satisfaction of all concerned. 40

Quena – Successful start-up of the world’s most modern bagasse paper mill

Egypt’s largest mill for graphic papers cal Luxor where papyrus paper was al- and newsprint started up in December ready made four thousand years ago. The 2000 when the first finished paper roll mill is right next door to a sugar factory, was turned out by PM1. Meanwhile pro- which provides bagasse – or cane trash – duction output has developed according as raw material for the neighbouring to plan, meeting all expectations for stock preparation line. high quality grades. Quena Newsprint Paper Co. (QNPC) is a The author: Bernhard Häussler, private investment company whose Paper Machines Graphic shareholders include some of the largest banks, insurance companies, sugar and food industry organizations. Headquar- At the beginning of 1998 Quena News- tered in Cairo, QNPC has greatly expand- print Company, Kous/Egypt ordered from ed its activities over the last few years. Voith Paper a complete production plant for graphic grades using bagasse furnish. This turnkey project was realized in an Kous is located in Quena province, upper amazingly short time. The impressive size Egypt, only about one hour from histori- of the Kous mill reflects the owner’s fore- Paper Machines 41

Fig. 1: Quena PM 1.

Fig. 2: The paper machine building at Quena Newsprint Company’s Kous mill in Egypt.

been producing high quality graphic pa- Kous mill the largest of its kind in the pers from bagasse – a very difficult raw whole of Africa. material to prepare and process. Smooth and successful commissioning was en- Thanks to mature process technology and sured by Quena and Voith Paper engi- the perfectly integrated functioning of all neers together with a team of experts Voith Paper components, this plant oper- from Tamil Nadu in India. ates smoothly and completely trouble- free. Tamil Nadu Newsprint and Papers Ltd. have been producing newsprint commer- The ModuleJet™ headbox ensures an ex- cially from bagasse in India since 1996 tremely stable basis weight cross-profile, on a Voith Paper line. This was the first with an independently controllable fibre time in the history of newsprint produc- orientation cross-profile. Optimal formation that 100% bagasse had ever been tion and runability are ensured by the

1 used as raw material. Right from the be- DuoFormer CFD gapformer, which en- ginning of the Quena project, full advan- ables active control of ash and fillers dis- tage was taken of the experience gained tribution on the z-axis. in India. PM 1 is equipped with the extremely reli- sight and pride in future-oriented tech- Quena will be producing in their new mill able NipcoFlex™ shoe press technology, nology for high quality products at com- 144,000 t.p.a. of graphic papers and for maximum dry content after the press petitive market prices. newsprint with basis weights from 40 to with optimal sheet volume retention. 80 g/m2. The furnish used will comprise The TopDuoRun dry section ensures Decisive for this contract award were 70-85% bagasse. This makes Quena’s unsurpassed drying efficiency, while Voith Paper’s outstanding references and technological leadership in machinery for 2 producing newsprint and graphic grades from yearling bagasse. Voith Paper is the only comprehensive supplier worldwide of this technology, covering both stock preparation and paper machinery. Voith Paper reference plants using bagasse furnish are operating in India, Indonesia, Pakistan, Bangladesh and Iraq.

Ever since the Kous mill was commissioned in mid-December 2000, it has 42

Fig. 3: SpeedSizer.

Fig. 4: The bagasse raw material depot.

Fig. 5: PM 1 reel section.

4 SpeedFlow™ and tandem soft-calenders ensure perfect sheet surface quality.

Apart from the complete paper machine, the Voith Paper scope of supply also included the entire stock preparation line, the approach flow section, whitewater systems and rejects processing.

Stock preparation is initially in four lines. The first two lines process mechanically and chemically bleached bagasse pulp respectively. The other two stock preparation lines process imported chemo- thermomechanical pulp (CTMP) and bleached pine kraft pulp (NBKP). These

Main paper machine data: Design speed 1,300 m/min Wire width 6,800 mm Sheet width on poperoller 6,180 mm Full paper reel diameter 2,800 mm Max. weight of full paper reel 35 t Production output 400 t/24 h Max. reeling speed 2,500 m/min Max. roll diameter 1,500 mm 43

two bagasse and two imported pulp The Voith Paper scope of delivery also in- and environment-friendly wastewater dis- grades are combined in the mixing chest cluded a TORO winder with roll transport posal. Well-equipped servicing and main- with recirculated broke, and then and packaging system, furthermore the tenance facilities are also provided. processed through the trim refiner. additives processing system with piping Newsprint is produced here with about and vats, and the overall process control Due to the extremely tight schedule for 40 % mechanically and chemically pro- system. Our consortial partner Alstom paper machine manufacture and pre- cessed bagasse, and 10 % each of CTMP supplied the drive systems and all electri- assembly, including all main line compo- and NBKP. The graphic papers made here cal installations including the DCS and nents, logistics coordination among the comprise 75 % chemically processed QCS systems. suppliers was a large-scale operation. bagasse and 25 % NBKP. Site erection was carried out by Egyptian Electrical power is generated on site by subcontractors with the support of Voith The main components of the approach an oil-fired high pressure steam turbine Paper supervisors. flow section are a 5-stage cleaner and a aggregate. Pass-out steam is taken from 3-stage screener. A disk filter supplied by this boiler for low pressure process re- Voith Paper took over all plant engineer- Andritz AG, Graz ensure optimal fibre requirements. Modern water treatment and ing, and was also responsible for the en- covery. effluent systems ensure freshwater purity tire scope of delivery including comprehensive technical installations inside the paper machine building. Except for exca- vation and structural work, the complete turnkey paper mill was thus delivered to the customer’s full satisfaction.

A further paper machine is planned for the future, and the necessary infrastructure is already installed. 44

Perlen PM 4 “Pionier” An illustrious inauguration ceremony and open day

On Friday May 4, 2001 Perlen’s new This comprehensive tour showed in par- paper machine PM 4 “Pioneer” was ticular how the PM 4 line is custom- inaugurated. Starting at the wood yard, tailored to specific market needs as well visitors enjoyed a tour of the TMP and as various logistics and infrastructure deinking stock preparation line right factors: through to the finished paper roll The production capacity of PM 4 is dispatch. All points of interest were adjusted on the one hand to regional posted along the route, including furnish availability, and on the other auxiliary systems such as effluent hand to local paper market capacity The author: treatment, the in-house hydropower within a certain radius. Bernhard Stützle, plant and boiler room. Perlen Paper Paper Machines Graphic personnel were on hand at every point The uniformly high furnish quality for answering detailed questions. required for LWC grades was ensured not only by rebuilding the modern TMP line already existing, but also with a new post-treatment line precisely 45

Fig. 1: Perlen PM 4.

Fig. 2: SpeedFlow.

adapted to these needs. Perlen is the 2 only paper mill so far where this concept has been realized.

As another special feature, semi- finished stock preparation capacities for TMP and DIP are sufficient for newsprint production both on PM 4 and on PM 5. This ensures a high degree of flexibility and adaptability to market fluctuations.

The new line is installed right in the heart of the existing mill, in the space previously occupied by an old paper machine. 46

The highlight of this one-hour tour was of functioned perfectly – as would be expect- other suppliers had been working inten- course PM 4 itself – already in commer- ed of Perlen Paper – with a shuttle bus ser- sively toward this inauguration highlight cial operation. More than five hundred in- vice to Perlen from the enormous parking – with some astonishing achievements vited guests were able to see for them- lot on the military airfield nearby, and since then as well. selves the online production of “Perlen- even a special train to and from Lucerne. top” coated high-gloss offset paper.PM 4 In a system consortium comprising dele- lived up to its “Pioneer” name by produc- To celebrate the occasion, this special gates from Perlen, Voith and partners, ing nearly 500 tonnes of “Perlentop” in train was pulled by Perlen Paper’s loving- Omya and Dow Europe, a good deal of 24 hours without a single tear-off. ly restored steam locomotive dating back development work was done already be- to 1911 – a great attraction for visitors! fore the order was received, together with On the following open day, the same tour extensive tests on pilot plants. The entire was available to the public. Once again, Right through the day, Perlen Paper Man- team always worked together on the PM 4 production in shift operation went aging Directors Schaller and Maisch were whole process line, focusing above all on smoothly, undisturbed by no less than on the spot with their entire team to en- stock preparation, coating and calender- thirteen thousand visitors filing continu- sure smooth operations. Feedback from ing.Overall results were regularly checked ously past the machine. 13,000 guests – including about one hun- by printing tests in practice. dred Voith Paper technology people – Operations were equally continuous at was very enthusiastic. The intensive preparations bore first fruit the other end of the line in the restaurant at the commissioning in September 2000. marquee, where visitors enjoyed the hos- Ever since the beginning of this project, After a brief start-up phase with news- pitality of Perlen Paper Ltd. The logistics the Perlen-Voith team and a good many print, LWC was already being produced in 47

Fig. 3: Janus MK 2 and Sirius.

Fig. 4: Visitors to Perlen on open day.

Fig. 5: Reel section.

5 October 2000. The specified product quality characteristics – gloss, printabili- ty and press room runnability – were attained unusually quickly.

The very high yardstick set for overall machine efficiency was not attained as rapidly as planned. During the commissioning and optimization phase, however, the entire well-versed team of experts was on hand with all the experience they had gathered during this project. Individ- ual optimization steps were planned and implemented in working groups, with such success that in the meantime production output is well above the start-up curve. Daily outputs of around 550 tonnes are in the vicinity of the calculated gross production output. In April 2001 the operating efficiency of PM 4 had already reached about 82 % – an excellent level 48

7 8 Fig. 6: Perlen’s veteran steam locomotive.

Fig. 7: The Swiss doctor and balloonist Bertrand Piccard.

Fig. 8: Perlen Paper Managing Directors Schaller (right) and Maisch (centre) welcoming guests.

Fig. 9: A group of visitors admiring PM 4.

9 for a machine with on-line coater and online calender.

At the inauguration ceremony, a brilliant address on Excellence was given by the Swiss doctor Bertrand Piccard, who in 1999 was the first to circle the globe non-stop in a hot-air balloon in only 20 days.

He emphasized that this record-breaking achievement was only possible thanks to teamwork, and explained the success factors which such a project team must ful- fil. For the Perlen PM 4 “Pioneer” team, this was an excellent opportunity to draw parallels with their own work. For our ongoing teamwork in this system partner- ship, we shall pay particular attention to one of Dr. Piccard’s principles: Never give up until you have reached the target. It is certainly a realistic medium-term target not only to attain the specified performance figures with PM 4, but to exceed them. 49

1 Kaukas PM 1 – A Finnish success story

In March 2000 the UPM Kymmene 1988. At the beginning of 2000, UPM Corporation, Helsinki, Finland awarded Kymmene decided to optimize this line, Voith Paper a rebuild contract for paper and placed their trust in Voith Paper. machine 1 and coating machine 1 in their Kaukas mill. In January 2001 this large Finnish project with a total invest- Decision ment volume of 30 million Euro was crowned by successful commissioning Decisive for the award of this order to The author: Klaus Hutter, right on schedule. Voith Paper was not only the well-found- Paper Machines Graphic ed technical concept, but also the satis- Case history faction of UPM Kymmene with their Jet- Flow-F coating aggregates delivered by The first production line at UPM Kymme- Voith Paper in 1996. Other important ne went into operation back in 1975. De- grounds were the outstanding reputation signed for manufacturing LWC and MWC of the DuoCentri-NipcoFlex press and the rotogravure and rotary offset magazine extreme compactness of the new Module- printing grades, the machine had been Coater, making it ideal for installation in producing 2-sided coated grades since the existing coating machine. 50

Location per production as well as machine capac- very high dry content with optimal ity. To achieve this, some innovative re- sheet volume. The UPM Kymmene Corporation’s Kaukas build measures were necessary: EnviroScan system for measuring mill is located about 150 kilometres east The paper machine operating speed was humidity cross-profile after the press of Helsinki in Lappeenranta. This compre- raised by 300 m/min to 1,600 m/min. section. hensive plant incorporates the following Simultaneous pre-coating was integrated Dryer section rebuild to the DryStar facilities: sawmill, in-house power sta- into the coating machine, whose speed concept, for greater reliability and tion, chipboard, pulp and paper produc- was raised to 1,800 m/min. stability of ropeless end transfer. tion. About two thousand three hundred Complete new hard-nip calender with people work here. The Kaukas mill has The scope of supply included the follow- thermo and Nipcorect rolls for cross- customers throughout Europe, its main ing machine components and aggregates: profile correction. market being Germany. Fibron threading systems for ropeless Paper machine: transfer through the calender to the New bottom wire return to ensure poperoller. Rebuild goals and scope of delivery stable running in the wire section. Coating machine: New PM press concept comprising a ModuleCoater installation comprising The purpose of this rebuild was to further DuoCentri-NipcoFlex press with shoe- a SpeedCoater coating aggregate and improve the high quality of magazine pa- press in the third nip. This ensures a a ModuleDryer afterdrying section. Paper Machines 51

Fig. 1: UPM Kymmene Corporation’s Kaukas mill in Lappeenranta.

Fig. 2: Kaukas PM 1.

Fig. 3: NipcoFlex press section.

Fig. 4: Comparison: before and after rebuild.

Special features 4 Before rebuild

For the first time worldwide in an offline OMC 1 RR 1 PM 1 coater, simultaneous precoating by SpeedCoater has been implemented. The ModuleDryer newly developed in team- OMC 2 RR 2 PM 2 work with Spooner Industries enables 2-sided contactless drying over a very OMC 3 short distance. With this Voith Paper technology application, double-coated After rebuild

MWC paper can be produced at the SpeedCoater with ModuleDryer New: Calender NipcoFlex Press Kaukas mill in a single run instead of using two offline coaters as previously. Due OMC 1 RR 1 PM 1 to the high resultant efficiency, the in- Relocated unwind DryStar Concept vestment is very worthwhile. OMC 2 RR 2 PM 2

OMC 3 52

Planning, design and installation During the main installation phase, the coating machine aggregates were thor- Kaukas workforce grew by more than 800 oughly tested and coordinated. The first building modifications were car- people, about 400 of whom from Voith ried out only three months after receipt Paper. Operating trials started before the of order. Rebuild planning and design installation completion deadline, and the Commissioning was completed in less then seven control system was tested for the first months. time under actual operating conditions. Since January 2001 the Kaukas produc- Two months before, FA tests had been tion line 1 has been turning out double- To ensure smooth and trouble-free instal- carried out under dry conditions at coated MWC paper in STAR quality. On lation, all aggregates were works-assem- Honeywell Measurex. January 14 commercial paper production bled in Heidenheim and Krefeld. Almost was attained for the first time, at a speed 100 truckloads were required for trans- More than twenty commissioning engi- almost as high as the top speed prior to porting the components to Lappeenranta. neers ensured that all paper machine and rebuild. Likewise in January 2001, the Paper Machines 53

Fig. 5: Kaukas coating machine 1.

Fig. 6: Layout of coating machine 1.

Fig. 7: The Kaukas project and commissioning team.

ModuleDryer

SpeedCoater 2 x 8 g/m2

Blade Coater 1

JetFlow F

existing OMC new Precoater relocated unwind

mill production and speed records were broken. Only three months after commis- Statement by Pentti Hirvonen sioning, an operating speed of 1450 m/min Kaukas Project Director was attained. Dry content after the press section at this time was already more The teamwork in handling and success- than 50%. The coating machine commis- fully completing this project is an sioning was also extremely successful, exemplary reference for future projects. with operation for up to twelve hours All the new components and modules shortly afterwards free of any tear-off. were optimally integrated in the existing line, thus not only ensuring successful The customer was very impressed with commissioning, but already breaking our the smooth and trouble-free installation, mill production and speed records. optimal commissioning, and perfect teamwork with Voith Paper. 58

Hürth PM 1 – The most cost-effective production line for standard newsprint

At the beginning of March 2001 – only months later on August 1, 2002, the new 18 months after starting up PM 5 at the line built on the “One Platform Concept” 100 % Myllykoski subsidiary Lang has to start producing standard news- Papier in Ettringen – Myllykoski again print from 100 % recovered paper. decided for Voith Paper. This time as supplier of the new production line for The overall investment budget of 280 newsprint at the Hürth mill near million Euro for this new production line Cologne. includes not only the paper machine, The author: Thomas Schaible, buildings and infrastructures, but also Paper Machines Graphic the complete stock preparation line as The Myllykoski project team finalized shown in Fig. 1. The scope of supply cov- their specification for the stock prepara- ers a new pulping and screening drum tion and paper machine lines in a very concept with a feeding system supplied short time: from mid-December 2000 to by B+G, hole and slotted screening, pre- the end of February 2001. Only 16 flotation and afterflotation, disperging,

1 Loop I Loop II PM Loop // 0.15 2 Flotation 1 Drum pulper HP cleaner MC screener fl 1.0 Dumping tower LC screener Disk filter 1 Screw press EP disperging Flotation 2 Disk filter Storage HW cleaner LC screener Paper machine

Separator DAF 3

DAF 1 Save All

Rejects Sludge PM handling handling spray water DAF 2 Paper Machines 59

Fig. 1: Deinking line, 2-loop system.

Fig. 2: Layout of Hürth PM 1.

Fig. 3: The contract signing ceremony (from left to right): Harry Hackl, Dr. Hans-Peter Sollinger, Thomas Nysten, Managing Director Myllykoski Continental, and Bernhard Ludwig, Managing 2 Director Lang Utzenstorf.

3 Decisive for the award of this contract was not only Voith Paper’s outstanding system competence, but in particular the experience with newsprint production from 100 % recovered paper.

The concept for this new line was drawn up to meet the following requirements: budget compliance without sacrificing quality or existing standards; full integra- tion of feedback and findings from previous projects for optimal copying effect with additional plant components; the concept must take full account of market requirements on standard newsprint over the next ten years. and the entire stock/water loop system plenty of recovered paper is available as including rejects handling. Our joint ven- raw material, and the end customers are By using well-proven components, sys- ture partner Meri is supplying the water/ not far away. tems and process stages, the shortest rejects handling systems, while the de- possible commissioning time should be watering machinery is supplied by our Hürth PM 1 comprises a ModuleJet head- ensured and the design production out- licensee Andritz as consortial partner. In box, DuoFormer TQv, Tandem NipcoFlex put reached as quickly as possible. The addition to the paper machine Voith Paper press, TopDuoRun dryer section, single goal agreed between Voith Paper and is also supplying the quality control sys- soft-nip Calender and Sirius. Since the Myllykoski for Hürth PM 1 is to attain the tem, sheet inspection and tear-off analy- introduction of this concept, the new world’s best start-up curve for this kind sis system, and all local controls. paper machine already incorporates the of line. eighth Tandem NipcoFlex press and the The Hürth location was chosen for vari- fifth DuoFormer TQv – thus making it the ous reasons: power, steam and water are seventh line in only two years to be built provided here from a local power station, on the “One Platform Concept”. 60

1 Kehl PM 2 – Large new production line ordered for special graphical grades

Eleven months after the successful age on the thermoreactive paper surface. commissioning of their new PM 6 for Since thermal printers and copying ma- decor papers, August Koehler AG, chines save considerable time and costs Oberkirch again placed a large order in office communications compared with for expanding their Kehl mill: a new conventional printing methods, there is a production line for thermo-papers. growing demand for thermopapers. This growth is likely to continue for some Installation work on this new line has al- time, since the processing possibilities, The author: Heinz Braun, ready begun. Production is to start in rapidity and flexibility of thermoprinting Paper Machines Graphic only sixteen months’ time, and commis- have not yet been fully exploited by any sioning is scheduled for December 2001. means. That will mark the start-up of Europe’s most modern and powerful production It was only logical, therefore, for August line for non-impact printing papers. Koehler AG as a leading producer of special graphical grades to expand their ther- Non-impact or thermo-papers comprise mopaper production according to market special wood-free grades which can be demand. Decisive for their choice of printed thermally, and without contact as Voith Paper as supplier of this new pro- for example in inkjet printing. The printer duction line was our outstanding partner- is heated electrically up to about 160° C, ship recently in the planning, installation at which temperature the inks combine and commissioning of PM 6 for decor with developers to generate a printed im- papers.

Main data of Kehl PM 2: Product thermal basis papers, 40-80 g/m2 Web width on roller 4,200 mm Design speed 1,500 m/min Operating speed 1,400 m/min Gross output up to 390 t/24 h Production capacity about 120,000 t.p.a. Paper Machines 61

Fig. 1: The August Köhler AG Kehl mill.

Fig. 2: Coating machine layout.

Fig. 3: Layout of the new PM 2.

Apart from design planning and engi- MasterJet G headbox and ing. Particularly important here is a uni- neering, this large new order also covers DuoFormer TQv (vertical gapformer) in form, high quality coating, which is en- substantial parts of the stock preparation the forming section to ensure optimal sured by a special coating aggregate de- line such as the charging, pulping and re- uniformity in the macro range (cross- veloped for this purpose by Voith Paper fining aggregates, rejects handling and profile and machine-profile) and micro in teamwork with the customer. The joint the approach flow section. Main focus is range (formation). venture signed between Voith Paper and on the new PM 2 and on the offline coat- DuoCentri-NipcoFlex press for out- IHI, Japan, also enables in Kehl the first ing machine for thermal printing paper. standing runability with high dry con- application of a curtain coater working The scope of supply also includes the re- tent and high pre-coating smoothness on the uniform 1:1 coverage principle. reeler, paper roll transport system and on the reverse side for thermo printing. August Koehler is the first paper manu- packaging machine. Single row TopDuoRun dryer section facturer to use a curtain coater at operat- for rapid drying and optimal availability. ing speeds above 1,000 m/min for this The Kehl mill’s new PM 2 will set new EcoSoft softcalender after the predry- special product – a pioneering milestone! milestones in thermo basis paper producing section for efficient precalendering tion. and a uniform thickness cross-profile. After commissioning, this new produc- SpeedCoater for good contour or in- tion line will be described in detail in one To meet the high quality demands, the sulation coverage as basis coating for of the next editions of “twogether”. It will latest components of the Voith Paper thermo-printing on the reverse side. certainly expand the position of August “One Platform Concept” will be integrated Koehler AG in the high grade thermopa- in PM 2: In the offline coating machine, the sheet per sector and consolidate the company’s is covered with a thermosensitive surfac- market leadership in Europe.

3 62

1 ... continuation. Janus™ MK 2 for Schongau PM 9

Review: when our previous article on The new PM 9 is equipped with a Janus™ the PM 9 rebuild in Schongau went to MK 2 – the most modern calendering press, we were just about to embark on technology currently available on the one of the most demanding installation market. The concept was new, it had to and commissioning projects ever under- be installed and commissioned in record taken worldwide. In only 56 days, not time, and the start-up curve was daunt- only did an existing paper machine have ingly steep. to be dismantled and systematically packaged for shipping to its new owner All technical preparations for this project in China, but its place had to be taken had been made in close teamwork be- by a new line due to start production at tween the customer and the supplier. the end of June 2000. Standstill time was scheduled right down to the last hour. All units had been commissioned previously next to the operating paper machine. In Krefeld a task force team of designers, automation and production experts was on hand around the clock for fast response to unavoidable The authors: surprises, as far as possible leaving Peter Herbrik, nothing to chance. All possible prepara- Franz-Josef Schmitt, Christian Münch, tions had thus been made – but were Finishing they enough? Finishing 63

Fig. 1: The first paper roll produced by PM 9.

Figs. 2 and 3: Frame erection and roll installation.

Fig. 4: Regular commissioning conferences – outside in the sunshine whenever possible.

To put the reader’s mind at rest – the an- stalled, ready for commissioning (Figs. 2 On June 8, 2000 the rolls were heated up swer is yes. In Fig. 1 you can see the ex- and 3). to 240 °C oil temperature, and on June hausted but happy commissioning team 15 the Janus MK 2 hydraulic system was next morning on June 28, 2000, standing Old hands at commissionings know only operational. On June 18 the drives were in front of the first paper roll turned out too well what surprises they can bring – run up to 2,200 m/min, and three days by PM 9. and Schongau was no exception. There later both stacks were closed for the first were not only surprises, mostly of the time at full speed and loaded to maxi- Let us now go back in time, however. unwelcome kind, but also breakdowns mum pressure. Punctually on May 2, 2000 the old PM 9 and extremely frustrating delays. But the produced its last paper roll and was situation was always saved by the well- When the countdown had reached 96 ready for dismantling. At the same time versed customer-supplier teams, who hours to zero, the end aggregate transfer in Krefeld the 400-tonne Janus MK 2 cal- had spent twelve months preparing them- system was started up with an unroll ender was being dismantled and pack- selves technically and getting to know stand specially developed for this project. aged in erection-friendly units for trans- each other personally. This disciplined port. The task of setting up the frames teamwork between the highly motivated was practised once again – for there Haindl people and Voith Paper’s would be no time for mistakes later on. expert commissioning engi- Dismantling of the old paper machine neers worked so perfectly, was not even finished when the end ag- that even the most ob- gregate foundations for the new one were stinate problem was already installed. And when the Module- solved in the end. Jet™ headbox foundations were poured, the Janus MK 2 frame was already in Coordination was time- place. This high-precision teamwork be- consuming. Two com- tween the customer and supplier, civil missioning conferences were works contractor and erection people was held every day between the cus- fascinating indeed. By May 25, 2000 the tomer, supplier and subcontractors Janus MK 2 had been completely in- (Fig. 4). 4 64

Figs. 5 and 6: Final optimization work by the transfer team.

Fig. 6: Start-up curve of PM 9 in Schongau.

Figs. 7 and 8: The Janus MK 2 calender.

56This was when the transfer team came 600 566,77 t into play. Day and night they balanced Production the commissioning parameters between Target dryer cylinder 38, the Fibron vacuum 500 tapes, the rope guide system, the pull stack and the Sirius™ winder. In the meantime the sheet reached dryer cylin- 400 der 38 several times. By now, the commissioning preparations on the paper

Production [t/day] machine were almost complete, and the 300 Janus team would soon be able to transfer their first sheet (Fig. 5). Jul Oct Jan AprJul Oct 2000 2001 On June 28 the big day came. The sheet was running at 1,330 m/min on dryer 7 cylinder 38 in the pulper. Everyone held their breath when the commands “Janus transfer on” and then “Sirius transfer” were given. The first shot was a bullseye! The double blade cutter divided the web, and the first reel was soon wound... although at first with a thickness of 250 mm (Fig. 6).

The next few weeks were demanding but rewarding. The transfer system had started up with impressive precision, and continued to do its job reliably. As shown by the start-up curve for the first month in Fig. 6, performance expectations were significantly exceeded. The paper machine efficiency already reached 78 % only two months after commissioning, and improved to 85 % after six months. At the present time, more than 500 tonnes of paper are being calendered in the Janus every day.

The roll change team performance was particularly outstanding. Even the first roll change went precisely according to plan, and after a while, roll changes were taking significantly less than the guaran- 65

teed time. Meanwhile, roll changing has were still completed during the commis- from 100 % DIP must be complied with. become a routine task. sioning phase. This achievement was only The quality team continues to meet regu- possible thanks to optimal coordination larly for jointly optimizing the paper qual- Teamwork between the automation groups and the high motivation of all concerned. ity parameters on a systematic basis. was likewise exemplary. After intensive preparations followed by FAT (Factory Ac- What now? All working groups have been The Schongau PM 9 project has shown ceptance Test) runs, the control system‚ dissolved since then except for the quali- that through optimal planning and close process regulation and drive aggregate ty team, but the personal contacts made cooperation with the customer, short teams were well harmonized and able to are still in place. Over the next few standstill times and steep start-up curves solve all problems in a very short time. months, in well-proven teamwork between are possible. We pay tribute to all those Despite the very tight schedule, all the the customer and supplier, the demand- who participated in making this project necessary adjustments and improvements ing quality criteria for SCB production such a success. 66

1 New Service Center in Indonesia

On April 19, 2001 in the presence risks for the customer – including time of numerous customers, high-ranking and cost outlay – through really profes- representatives of the Indonesian sional services on the spot. Ministry of Trade and Industry, and the German ambassador, a new Voith Paper The new service center, which has nearly Service Center was inaugurated about 7,000 square metres of shop floor area to 60 km east of Jakarta. This is situated start with, already employs 50 profes- in Karawang Industrial Estate, well sionals, and medium-term expansion to a The author: connected logistically with the West staff of around 100 is planned. The crane Martin Scherrer, Service Center Jakarta Javanese pulp and paper industry and systems and the machine park, with mod- not far from Jakarta airport and harbour. ern CNC turning and grinding centers, multi-spindle boring machines and dy- namic balancing units, can already handle all roll types up to 15 metres long, The opening of this new service center weighing up to 100 tonnes and up to underlines the importance attached by 2,000 mm in diameter. Capacity can be Voith Paper to growth of the paper and added at any time according to need. board industry in South-East Asia, Aus- tralia and New Zealand, Taiwan, China The entire Voith Paper coating technolo- and South Korea. True to our principle of gy, both in rubber and polyurethane, is fast and partnerly customer service on already available here or possible at short the spot, this new center offers every- notice. The new service center thus offers thing required for professional customer exactly the same processes, materials, support – consulting and analysis, main- quality and delivery logistics as all other tenance and overhauls, and in particular Voith Paper service points in Europe or fast service for wear parts such as roll America. This also includes the former covers and stock preparation line compo- Scapa technology acquired by Voith nents. The main goal is to minimize all Paper in 1999. And in the near future, the Service 67

Fig. 1: The new Service Center in Karawang.

Fig. 2: Mertin Scherrer welcoming guests at the official opening.

Fig. 3: Ray Hall holding his welcome address.

Fig. 4: Roll center.

Fig. 5: Indonesian women in traditional costumes at the inauguration ceremony.

2 3 4

mechanical roll service equipment will be at all times. Thanks to close teamwork explained the latest state of clothing complemented by a Nipco test stand. Fur- with Voith Paper’s R&D people in North technology. Since January 1, 2001 Voith thermore, the new service center will America and Europe, the latest state of Fabrics serves the Indonesian market soon be offering comprehensive servicing technology has now been transferred to with its own qualified staff instead of via for anti-deflection rolls. So far most In- Indonesia. local agents. donesian customers had to send rolls of this type to Europe or the USA for recon- Guests invited to the opening of this new The substantial investment made by Voith ditioning. By the year 2002 the manufac- service center were able to see for them- Paper in this new service and support ture of composite covers for calender selves the impressive offering. Welding center will consolidate and expand on a rolls is also planned here. specialists demonstrated how rotors for long-term basis our fruitful cooperation stock preparation units are reconditioned not only with existing customers in the It goes without saying that field service is in Europe – a service also available in In- growing South-East Asian paper and also provided, such as vibration mea- donesia in future. Voith Fabrics people board industry, but also with new ones. surements, headbox repairs, dryer section repairs, roll changing assistance, and mobile roll grinding and thermal spray 5 coating.

Voith Paper is the only provider in the entire South Pacific region of such wide- ranging services on the spot. Not to be forgotten is the worldwide backing of Voith Paper research and development potential, which can be directly accessed 68

Voith Fabrics – A new millennium of paper machine clothing: Quantum II dryer fabrics

Choosing a supplier to the dryer part of Graphic Papers a paper machine has become more critical as we enter the new millennium. Investment in the European paper indus- This is because modern dryer section try during the year 2000 saw the start up geometry has evolved with the increas- of the new machines of Haindl Augsburg ing requirements for faster machine PM 3, Haindl Schongau PM 9, Hermes speeds, higher quality papers and PM 5, Soporcel PM 2 and Perlen PM 4. better fabric lives. Voith Fabrics Voith Fabrics is the only paper machine The author: Mark Hodson, continues to develop its dryer fabric clothing supplier to be chosen for the Voith Fabrics product range in order to maximise dryer part on all of these new machines. fabric performance on both new and The Hermes, Perlen and Schongau ma- existing paper machines. chines started up with 100% dryer clothing from Voith Fabrics.

In addition to the success on new machines Voith Fabrics have also supplied clothing to major rebuilds of European Fabrics 69

62.9

62 60.4

58 55.8

54 Fig. 1: Small Loop and In-line Spiral seams of Quantum II.

Fig. 2: Modern dryer section geometry. 50 Quantum II High Speed High Speed Fig. 3: Air volume (mm3/mm2) of dryer fabric 3 Fabric A Fabric B surfaces. paper machines. These include the rebuilt Voith Fabric’s products were fitted on the Quantum II gives effective transmittance dryer parts of Holmen Hallsta PM 2, Sappi first sections of Aylesford PM 14 (9.95 m of under pressures to the surface of the Gratkorn PM 9, Nordland Papier PM 4 wide) and Augsburg PM 3 (10.40 m wide) sheet for good sheet control. In addition and Haindl Schongau PM 7. In April 2001 on 14th February 2001. The seams on the available volume of air in the fabric PM 7 started up with Voith Fabrics on the these fabrics were meshed, seam wire in- surfaces is very low (Fig. 3) and this im- 1st, 2nd, 3rd, 4th and 5th single tier sec- serted and finished by the machine crews proves both tail feeding and sheet tions together with a fabric on the 6th top in less than fifteen minutes each. The runnability. Quantum II is already running position. Quantum II from Voith Fabrics seaming process requires fewer people to successfully at pilot machine speeds of runs on the world’s fastest machines pro- join the fabric, leaving operatives free for 2000 m/min. ducing graphic papers. other duties. Changing dryer fabrics can be very uncomfortable for machine crews The success of Quantum II is repeated on due to the temperature in the hood dur- the high-speed machines in Asia. The ab- Ease of installation and safety ing “crash shuts”. The ease of seaming sence of seam mark in the paper was an means that the machine crew is in the important requirement of dryer fabrics Improved seam technology and the hood for a shorter period of time and that for the start-up of the 1500 m/min PM 1 seaming aids used with the Quantum II the machine is soon available to start of Malaysian Newsprint Industries in De- (Fig. 1) design enable the dryer fabric to production. cember 1998. Quantum II fabrics gave be easily installed on sections where the best performance on the machine and there are narrow clearances within the are now running on 100% of the dryer fabric run, Fabric life, stability and performance sections. Several of these fabrics exceed- either long or short length fabrics have ed lives of 15 months and were still in limited stretch rack movement, Quantum II has a high material content good condition when safely removed at access is limited for seaming. and CMD stiffness. This is important be- planned shuts. cause dryer fabrics on high speed sections (Fig. 2) have to be more stable than In North America Quantum II is becoming 2 normal designs due to established as the high-speed fabric on critical sections of the paper machine. short length or wear prone positions, It has replaced other fabric designs at fabric return runs with no outside felt Alabama River News PM 1, Madison Paper rolls, PM 3, Appleton Papers PM 7 and the re- fitting allowances of only 1% and build start up of Willamette Johnsonburg fabric extension during life limited to PM 5. 1% with high running tensions, long unsupported runs between felt The performance of Quantum II in Europe, rolls Asia and North America shows it to be a high under pressures from sheet truly global product. control equipment. 70

Fig. 4: Paper contacting surface of Ultratherm.

High temperature applications paper grades. Ultratherm is constructed in North America and Europe. North from PPS monofilaments in both the ma- American successful installations on Many sections of packaging machines are chine and cross machine direction. It is board and packaging machines include able to achieve good lives with dryer fab- available with the same smooth contact Westvaco Evadale, Inland Rome and Unit- rics that are made of polyester or modi- area and aerodynamic surface of the ed Corstac Reading. Enduro fabric perfor- fied polyester material. However, higher Quantum II fabric construction. This mances have exceeded the normal lives steam pressures can lead to degradation makes Ultratherm an ideal choice for the of polyester fabrics and thinner calliper of the fabric edges outside the sheet new generation of high-speed packaging 100% PPS or 100% PCTA designs on deckle and it is necessary to run fabrics machines. abrasion prone positions. with PPS material at the edges to improve fabric life. PPS is unaffected by the heat and hydrolytic conditions within the Improved fabric life on wear prone New generation of fabrics dryer section. Steam groups within the sections dryer part can be up to 8 bar pressure Dryer fabrics are an essential part of the with cylinder temperatures of 160 °C Voith Fabrics introduced their latest dryer paper making process from the physical (320 °F). PPS material is also used when product line of Enduro in autumn 2000. It requirements of transmitting the drive chemical conditions on the machine are a is primarily designed to resist wear from between cylinders to the reduction of cause of degradation. Voith Fabrics man- poor felt roll conditions on hydrolysis shrinkage at the sheet edges. Modifica- ufacture several different PPS content prone positions. Enduro is a unique dryer tions to dryer fabric materials can be fabrics including Ultratherm and Enduro fabric construction that consists of large, achieved ‘in house’ through co-operative for sections with high-pressure cylinders, square PPS and PCTA machine direction development at our SynStrand monofila- depending on the severity of conditions monofilaments. The design gives a signif- ment extrusion facility. Trials on Voith within the hood. icant increase in the amount of material Paper pilot machines ensure that fabric presented to the fabric surfaces, resulting designs are proven to work on new sec- in better fabric lives on wear prone position geometry, prior to their installation Maximum resistance to degradation tions. Most applications are on machines on the paper machine. producing packaging grades of paper. Ultratherm is an established product line However the surface is smoother than the Voith Fabrics designers, application engi- that provides ultimate resistance to the normal coarse fabrics supplied to these neers and service specialists are integrat- highest levels of temperature and humidi- applications, resulting in a finer, more ing with Voith Paper as one team. This will ty (Fig. 4). It is mainly supplied to pack- uniform contact with the paper. This also provide a unique customer based influ- aging machines, although its applications makes the fabric suitable for other paper ence, feedback and knowledge that will re- include writings and printings and coated grades. Enduro trials have been supplied define the direction we travel in the future. Paper Machines 71

Fibron TT3000™ – Innovative tail threading at Lang Papier has proven a success

It is known that the efficiency of tail Additionally, in the event of a sheet threading from the last dryer is often break, such time-consuming distur- impaired on paper machines producing bances and cleaning at the take-off doc- grades with a high filler content (e.g. tor distinctly extend the production SC, LWC) due to an overstressed doctor downtime and reduce system efficiency, function in the tailing region. which is so important, particularly with online paper machines.

To ensure constant, reliable threading and an improvement in the entire threading process, especially on high-speed machines with online Janus calenders, it High-pressure water-jet tailcutters being was therefore necessary to develop a new operated at a very high cutting pressure method for the take-off of the threading (more than 900-1,000 bar) produce a tail. This method is based on the basic large quantity of cutting pulp at the take- idea of taking the tail directly off the dryer off doctor at high speeds. surface in order to be independent of any malfunctions at the take-off doctor. If the tailcutter is operated for a long time, this build up of pulp at the doctor The concept of using the already known results in adhesion of small paper shreds principle of the so-called “Bullhorn” take- at the doctor blade in the area of the cut. off seemed to suggest itself as this prin- These obstacles prevent the threading tail ciple had already been used successfully from stabilizing properly off in the pivot- on other similar applications. ing tail threading element, the flip tray, fastened under the doctor blade. Tail This principle was already tested some take-off and transfer into the following time ago at the last dryer of a production part of the threading system is therefore machine. However, for lack of testing unreliable and inaccurate. Tails with very time, sufficient flexibility of the testing The authors: Sylvain Demers, long and uncontrolled loops, called dou- equipment and of a sufficient number of Fibron Machine Corporation; ble tail, are often produced. In a very de- tests, this test did not produce any rea- Wolfgang Drefs, manding threading path such as a rope sonable results. Voith Paper Paper Machines Graphic; transfer system in an online Janus calen- Jim Dadd, der, this double tail often results in the It became obvious from this experience: Fibron Machine Corporation destruction of the actual threading tail during threading due to the knocking- that such a development could only be around, tear-off and adhesion it creates. implemented in the fastest and most efficient way on a pilot stand which Alternative doctor blades, precise adjust- simulates the real situation during the ment of the doctor combined with regular run-off of the paper sheet and cutting cleaning and regular blade changes only of the threading tail as precisely as New resulted in slight improvements in possible at the last dryer of a paper Product threading performance. machine; 72

“Bullhorn”

Table with airfoils

1 Fig. 1: TT3000™ foil configuration.

Fig. 2: TT3000™ in three positions.

2 was to use the new threading system on The concept the last dryer on PM 5 at Lang Papier in Ettringen. Threading to be independent of the doctor function The new test stand was designed for a Threading at any machine speed Store max. operating speed of 2,000 m/min. No looping (double tail) during take-off and comprised the following elements: Precise control of the threading tail during take-off An unwind device for feeding the test Functional reliability paper with a roll diameter of 125 cm and a roll width of 60 cm;

Ready A steel cylinder with pressure roll and The device doctor, arranged above a pulper, for simulating the last dryer; Operationally reliable Few moving parts 2 high-pressure water-jet cutting Self-cleaning nozzles cutting on the steel cylinder for simulating the tailcutter; Thread Moisturizing nozzles for paper-sheet Characteristics conditioning; Immediate readiness for threading, A new, long Fibron conveyor are without time-consuming doctor that a large number of tests have to be designed for installation at Lang Papier cleaning and other maintenance steps conducted using real operating para- PM 5; Safe initial tearing and separation of meters and taking speed, paper quali- the tail ty, basis weight, etc., into account; A test “Bullhorn” take-off device. Simple operation Non-contact solution that a functional reliability of almost The test was set up to simulate the actual Maintenance-free 100% must be achieved under test installation situation at Lang Papier PM 5 Retrofittable on existing systems conditions before installation in a run- as precisely as possible. possible ning paper machine can be released so that the risk of a time-consuming During the setup of the test stand, al- The construction of the test stand was restoration of the old components and ready existing components and machine started in the middle of December 2000. the production losses resulting from parts from different Voith Paper locations this are minimized in the event of in- could be used to a large extent. Because More than 400 threading tests were car- sufficient function. of this, the development time was very ried out and documented from the end of short. January to the middle of March 2001 by At the beginning of November 2000 it the R&D team consisting of employees was decided to start a development pro- The development of the new peeling-off from Voith Paper Coquitlam (Fibron), ject in the R&D center in Heidenheim. If and threading unit was based on the fol- Voith Paper Heidenheim and Voith Paper successful, the objective of this project lowing criteria: Krefeld. Paper Machines 73

Fig. 3: Prototype TT3000™.

Fig. 4: Production unit installed at Lang Papier, 3 Germany.

A great number of nozzle and Airfoil through and lifted off the dryer. The new 4 arrangements were tested during this pe- beginning of the tail resulting from this is riod. seized by the Airfoils in the table and guided to the subsequent Fibron convey- The use of a high-speed camera with 500 or. In this connection the “Bullhorn” noz- single pictures per second turned out to zles and Airfoils are controlled according be invaluable for the documentation of all to a sequence which was optimized in the nozzle and Airfoil arrangements and their course of the tests to minimize blowing effects on the peeling-off and threading time and maximize control and guiding of process. the threading tail. The duration of the entire blowing sequence is far below 1 sec- Only the evaluation of the high-speed ond. videos enabled us to fully understand the complex peeling-off process and thus to The new take-off device was launched optimize blowing sequence and blowing onto the market under the name Tear and time of the nozzles and Airfoils in the mil- Transfer 3000™ (TT3000™). lisecond range. Fig. 2 shows the three positions of the The breakthrough with the threading TT3000™: the park position, the ready tests at the R&D center in Heidenheim position and the threading position. Fig. 4 came at the beginning of March 2001. A show the device installed at Lang Papier. functional reliability of almost 100% was cutting pressure was reduced to 800-900 reached at a test speed of 1,800 m/min When the TT3000™ was started up on bar in the course of optimization. with the test “Bullhorn” take-off device PM 5, it turned out that there was an es- (Fig. 3). Shortly afterwards, the manufac- sential difference from the tests at the The most important result after a total ture of the final design of the “Bullhorn” Research Center in that the threading tail period of 6 weeks of optimization with all take-off device for installation on PM 5 at adheres much less to the dryer during operating modes, paper grades, basis Lang Papier was started. In mid-March practical operation. Peeling-off of the weights and speeds: the device was pre-assembled in the R&D threading tail from the dryer was much center. The installation in PM 5 took easier, but the lateral tear-in and tear- The production downtime after a sheet place on 26 March 2001 and the start-up through of the tail necessary for the cre- break has been significantly reduced, pri- from 30 March 2001. ation of a new tail beginning without a marily due to the elimination of the time- loop (double tail) was equally made more consuming disturbances and cleaning re- The final design of the “Bullhorn” take-off difficult. quirements at the take-off doctor. device consists of a table with four different Airfoils (Curly Foil, Foil 0, Foil 1 and One of the causes of this phenomenon Our customer, too, who has favored and Foil 2) and two laterally attached nozzles was the initially extremely high cutting supported this new development, has of the “Bullhorn” type. Fig. 1 shows this pressure of 1,500 bar at the tailcutter. The confirmed the functional and operational arrangement. consequence of this was that the cutting reliability of the new device. edges of the tail no longer rested flatly on By the explosion-like air blast from the the dryer surface and that blow air could Congratulations to the entire project team two “Bullhorn” nozzles, the threading tail already get behind the tail and peel it off for a job well done and completed on is initially torn at the side and then torn the dryer before it was initially torn. The schedule. 74 Paper CULTURE

Creativity with Paper

Despite the availability of plastics and a ling card produced? In Esslingen, near display at the J.F. Schreiber Museum in whole range of kits made up of perfectly Stuttgart, there is a small museum the south German town of Esslingen, sit- reproduced pieces, the good old tech- where visitors can admire treasures uated on the River Neckar. And they are nique of modelling with paper and card from the early days of modelling paper all made of paper or card. is currently undergoing a worldwide and card printing. renaissance. Unlike almost any other The J.F. Schreiber Museum tells the story type of hobby involving personal skill An accurate model of a ship, the set of of world-famous publishers J.F. Schrei- and creativity, it inspires dreams and Goethe’s Faust in miniature, a model of ber, still a going concern in Esslingen. flights of imagination in the hearts of the human body that can be taken apart With its picture books, sheets of model- children and adults alike. Where were to show the various organs – what do ling card and children’s books with mov- the first ready-made sheets of model- they all have in common? They are on ing parts, this company has contributed 75

something significant to Germany’s cul- battles from previous centuries. Next, Fig. 1: Everything is to scale in paper and card – tural history. you enter an accurately reproduced litho- whether it’s a historic castle, a crane portal, the “Imperator” express steamer, an aircraft or a graphic workshop which gives you an au- local tram on the Teltow line. When you enter the museum, which is thentic impression of the early history of housed in a historic building on the edge picture printing. At that time, new tech- of the old quarter of Esslingen, you im- niques such as lithography were giving mediately feel you have stepped back in wide public access to visual reproduc- time. At the beginning of the tour, you tions of many different kinds. In a side cross a corridor with display cabinets room, there is a theatrical set reproduced containing among other things paper re- in paper and, as you continue, you will productions of historical buildings and see examples from an extensive range of 76

Fig. 2: The lithographic printing technique, in which illustrations engraved on steatite are 3 pressed on to the paper, permitted long and therefore inexpensive print runs.

Figs 3 and 4: “Pictures for Visual Instruction from Esslingen” – accurate reproductions of animals and plants on boards for use in the classroom.

Fig. 5: Paper theatres were very popular among educated people at the turn of the century.

2 educational institutions. These “Pictures for Visual Instruction from Esslingen” were a decisive step in expanding the publisher's list. They replaced the more or less primitive visual aids then available with accurate pictures. In 1850, there were already 90 of these boards, illustrating trades, agriculture and aspects of the animal and plant world. They also illus- sation in book production”. New printing trated special geographic features of Ger- techniques such as lithography were many, Europe and foreign climes. In the making it possible to produce illustrated museum, visitors have an opportunity to books at considerably lower cost – and browse through draft designs that have Schreiber was a master of this technique. not previously been seen by the public. cardboard models, display boards used The publisher’s business was originally for educational purposes and historic focused on holy pictures and pictures of children’s books from the publisher’s the saints. Schreiber was very successful archives. at marketing them.

J.F. Schreiber – a revolutionary in the graphic arts Boards pave the way to a full publisher’s list Who was Jakob Ferdinand Schreiber? The founder of the publishing house that In 1833, Schreiber began to publish bears his name was born in 1809 and colour illustrations for schools and other grew up as an orphan. His talent for drawing, which was discovered at an early age, led him to the art academy run by 5 Georg Ebner, where he worked as a draughtsman and illustrator. It was there that he discovered an enthusiasm for the From 1877 onwards, the paper theatre “new and amazing potential for graphic began its triumphant progress, becoming and artistic creativity”. He was fascinated extremely popular as a form of family en- by the problem of reproducing and dis- tertainment. The museum has various se- tributing these creations in a relatively lected examples on display and some of short time. them can be purchased as reproductions.

The publishing house had another suc- Pictures of the saints cess in 1892 with Schreiber’s four large anatomical wall panels showing the hu- Schreiber grew up at a time when Europe man body with paper components that was being swept by a fashion for “visuali- 4 could be disassembled. 77

Schreiber cutouts were later added to the The first high-speed printing machine in 1904, when J.F. Schreiber installed an range. These were handicraft and model- Germany American two-revolution printing press ling patterns that could be cut out of made by Miehle. In the same year, colour sheets showing interesting buildings, In 1832, Schreiber bought its first letter- illustrations produced by the letterpress cut-and-assemble pictures and activity press printing machine and in 1864, technique appeared for the first time as a sheets. The range still includes model- Ferdinand Schreiber, the older of J.F. magazine. Colour printing went through making sheets of cars, aeroplanes and Schreiber’s two sons, imported the first an intensive process of development at ships. The museum has about 500 exam- high-speed lithographic press to Ger- the Schreiber company before and after ples of these cardboard models. many from France. They were soon able the First World War. In addition, a new to claim to be “the first printers in Ger- department dedicated exclusively to the many to use the letterpress method for careful and perfect reproduction of The “Wurzelkinder” lithographic printing”. Schreiber was on posters, brochures and advertising mate- and other picture books its way to conquering a world market.The rial by offset and letterpress printing for extent to which technology dominates the large-scale industrial and commercial Children’s books were an important part publishing business was also evident in customers was set up. of the range. Perhaps the most famous on Schreiber’s list, and still a firm 7 J. F. Schreiber has been having renewed favourite today, was “Etwas von den worldwide success recently with reprints Wurzelkindern” (“The Children of the of pop-up picture books from the last Root Bowl”) by Sibylle von Olfers. There century, presenting as it were the ‘history is a special section of the museum devot- of the story’. ed to it. The children of the title live un- derground – and that’s where they are Fig. 6: In the “Root Bowl”, adults and children in the museum too. In the “root bowl”, can experience the life of the “little people”. children can experience the magic of the Fig. 7: Even in the computer age, children can “little people” for themselves. still be creative with paper.