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JANUARY/FEBRUARY 2014

DRYER SECTION PERFORMANCE Five easily applied dryer performance indicators make way for optimal energy efficiency

CONTAINERBOARD Capacity bulge, sluggish demand remain challenges for containerboard market In Tune for Sustainability, Agility and Profitability

HigHligHts • Tissue360° Forum • State of the Industry • OpEx Reliability Workshop • Sessions • Executive Panel • Coating Sessions • Expanded Exhibit Hours

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Reliability OpEx Workshop Joining PaperCon: at PaperCon 2014 FORUM contents JANUARY/FEBRUARY 2014, Volume 130, Number 1

COLUMNS 14 Market Grade: Containerboard 2013 wasn’t a bad year for containerboard mills but results were decidedly mixed. Price increases were enacted on board and corrugated boxes in early 2013 that boosted margins, but underlying box demand was stagnant. 2014 offers hope that improved economic growth can propel box demand to stronger gains, but the impact of new containerboard capacity remains a nagging concern. 18 16 Heads-Up: Quiet Start in Europe The European industry is off to a relatively quiet start in 2014, and industry observers say the year may continue as such, which may be a FEATURES good thing. 18 Easy-to-Apply Dryer Performance 30 Recycling Matters Indicators Continuous commitment to paper recovery for The dryer section is a large consumer of energy, recycling paper recovery has fostered a dynamic but ensuring it is operating efficiently is not marketplace that allows recovered fiber to find difficult. By assessing only a few easily applied its highest-value use, which helps to encourage “dryer performance indicators”, one can deter- even more recycling. mine whether large improvement opportunity exists. DEPARTMENTS 22 Microbiological Auditing and 4 Editor’s Note Control – A New and Powerful 6 Industry News Approach to Controlling Problem Organisms 12 People A genetic-based technique used to detect and 13 Calendar identify troublesome microbes in paper mills’ fresh water systems has been found to be quick, accurate, and less cumbersome than traditional SERVICES methods. 29 Classified Ads 26 Keep it Running Smooth To succeed in today’s fiercely competitive market- 29 Index of Advertisers place, and paper manufacturers positively, absolutely, require maximum equipment availability and productivity from their machinery, and a disciplined lubrication management program can make this happen.

PaperAge JANUARY/FEBRUARY 2014 3 editors note

JANUARY/FEBRUARY 2014 If at first you don’t VOLUME 130, NO. 1 succeed… EDITOR IN CHIEF Jack O’Brien

By John O’Brien, Managing Editor PUBLISHER Michael C. O’Brien [email protected] MANAGING EDITOR John F. O’Brien, Jr.

CONTRIBUTING EDITOR Harold M. Cody

. . . try, try again. With that in mind, Verso improved if Verso was able to acquire CONTRIBUTING WRITER David Price Paper on January 6 announced that it would NewPage’s assets at fire sale prices or if debtors CONTRIBUTING WRITER John Yolton acquire NewPage in a deal valued at $1.4 fail to reorganize; (2) Verso is significantly LAYOUT & DESIGN George H. Dean Co. billion. This will be a very big deal if the two threatened by the possibility that NewPage companies can actually get past the initial will successfully reorganize under a stand- proposal stage. They’ve been down this road alone plan and emerge from bankruptcy a SALES OFFICE 20 Schofield Road before and it has been a very, very bumpy stronger, healthier company with a deleveraged Cohasset, MA 02025-1922 ride to say the least. balance sheet; and (3) Verso stands to benefit Phone: (781) 923-1016 Fax: (781) 923-1389 As some may recall, the on-again, off-again from any delays in the debtors emergence email: [email protected] romance between Verso and NewPage dates from bankruptcy and can be expected to Web Site: www.paperage.com back to 2010 and early-2011. At that time, oppose all stand-alone plan proposals and any EDITORIAL OFFICE private equity owners, Apollo Management near-term restructuring. 42A Country Way (Verso) and Cerberus (NewPage), were repor- Over the summer of 2012, the two com- Scituate, MA 02066-3743 Phone: (781) 378-2126 tedly in talks that most industry observers pre- panies sparred until Verso on Sept. 4 finally Fax: (781) 923-1389 sumed were about the combination of North called a halt to its pursuit of NewPage, stating email: [email protected] America’s two largest producers. that “it has decided to cease further discussions Web Site: www.paperage.com

However, many analysts pointed out that the with NewPage Corporation or its creditors Copyright ©2014 by O’Brien Publications, Inc. All rights reserved. PaperAge (ISSN:0031-1081) is published six two papermakers carried much too much debt regarding a potential business combination.” times per year with those issues being January/February, for the deal to make financial sense, especially Or maybe not. After a 16-month regroup- March/April, May/June, July/August, September/October, November/December by O’Brien Publications, Inc., to certain groups of lienholders. ing period, both parties, it seems, have had a 20 Schofield Road, Cohasset, MA 02025-1922. Periodicals postage paid at Cohasset, MA and additional Nothing, it appeared, but speculation change of heart and are in agreement to the mailing offices. resulted from those talks, and on September structure of a new deal (see page 6) — a very Publication Mail Agreement #40112731. 7, 2011, NewPage filed for creditor protection complicated deal. In a recent presentation by Canadian Mail distribution information: under Chapter 11. Verso, “NewPage Operating Company would Express Messenger International, P.O. Box 25058, London BRC. As NewPage moved into its tenth month be a non-guarantor restricted subsidiary for Ontario, Canada N6C 6A8 of reorganization, Verso on July 2, 2012 Verso’s notes with a standalone capital POSTMASTER: Please send change of addresses to: announced that it had “held discussions with structure.” PaperAge, 20 Schofield Road, Cohasset, MA 02025-1922. certain holders of the 11.375% first-lien senior Moody’s Investor Services explains it secured notes of NewPage Corporation in an like this, “It is anticipated that following the Subscriptions: PaperAge is mailed without charge in the U.S. and Canada (upon written request) to qualified effort to achieve a potential business combina- acquisition, Verso and NewPage will be run as individuals in the pulp, paper, , and paper tion involving Verso and NewPage as part of a separate legal entities with a shared services converting industries. To all others there is a subscription charge of $54.00 in the U.S., $60.00 in Canada, and consensual plan of reorganization in NewPage’s agreement.” $90.00 in all other countries. Single copies may be Chapter 11 bankruptcy proceedings.” Regardless of the complexities, Verso has purchased for $10.00 each. All payments must be made How did that proposal go over? Not very hung in there, I’ll grant it that. And although in U.S. funds and checks must be drawn from a U.S. bank. Credit cards are accepted. well; not very well at all. Just ten days after the there remains a lot of people to satisfy, includ- Reproduction of by any means of the whole or part of proposal, an attorney representing holders ing possibly antitrust regulators (Verso and PaperAge, without written permission, is prohibited. of first-lien debt strongly rebuffed the deal in NewPage would have at least 50% of the a letter to Judge Kevin Gross, U.S. Bankruptcy coated freesheet market), perseverance may Court in Delaware. The letter concluded that be the lynchpin that sees the deal through (1) Verso’s market position would be greatly this time around. n

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NORTH AMERICA Verso Paper to Acquire NewPage in $1.4 Billion Deal

Verso Paper and NewPage on expected to be achieved during the first 18 months after comple- Jan. 6 announced a definitive tion of the transaction. agreement under which Verso Dave Paterson will lead the combined organization. will acquire NewPage in a trans- Under the terms of the deal, NewPage’s equity holders will action valued at $1.4 billion. receive total cash and debt consideration of $900 million, con- Upon closing of the deal, the combined company will have sisting of $250 million in cash, most of which will be paid to sales of approximately $4.5 billion and 11 manufacturing facili- the stockholders as a special dividend prior to closing and the ties located in six states. remainder of which will be paid at closing, and $650 million of The transaction, which has been unanimously approved by new Verso first lien notes to be issued at closing. the boards of directors of both companies, is expected to close in NewPage’s equity holders also will receive shares of Verso the second half of 2014, subject to regulatory approvals. common stock representing 20% (subject to potential adjust- “The combination of Verso and NewPage will create a stron- ment up to 25% under certain circumstances) of the outstanding ger business that is better positioned to serve our customers shares as of immediately prior to closing. Certain of NewPage’s and compete in a competitive global marketplace,” said David J. stockholders owning a majority of the outstanding shares of Paterson, Verso’s President and CEO. NewPage common stock have agreed to vote their shares in favor “We continue to face increased competition from electronic of the approval of the transaction. substitution for print and international producers, but as a larger, Verso will finance the acquisition through $750 million in more efficient organization with a sustainable capital structure, we committed financing, which will be used to pay the cash portion will be better positioned to compete effectively and deliver solid of the merger consideration and to refinance NewPage’s existing results despite the industry’s continuing challenges. Furthermore, $500 million term loan prior to closing. we believe the transaction provides stakeholders in both The value of the transaction is $1.4 billion, composed of the companies with meaningful, compelling value,” Paterson said. cash consideration, the $650 million of new Verso first lien notes, The combination of the two companies is expected to result the Verso common stock and the refinancing of NewPage’s $500 in at least $175 million of pre-tax total cost synergies, which are million term loan.

SP Fiber Technologies to Convert Fox River Fiber Begins Use of Wastewater Machine in Newberg Mill to Pre-treatment Facility Lightweight Containerboard Fox River Fiber announced that it has SP Fiber Technologies, LLC (SPFT) announced plans to begun utilizing a $7 million wastewa- convert a newsprint machine at the company’s Newberg, ter pre-treatment facility designed to Oregon to produce lightweight containerboard. reduce the company’s environmental PM5 ceased production of newsprint on January 15 to impact from its pulp manufacturing allow for necessary process modifications, the company said. operations. The conversion is expected to be completed in the sec- The De Pere, Wisconsin-based ond quarter of this year. pulp manufacturer utilizes post- SPFT said that it will continue providing high quality, consumer fiber as its primary raw recycled content newsprint for the west coast market from material for making high-quality pulp. the mill’s PM6. According to the company, the on-site anaerobic digesting “This project reflects the strategy to grow our packaging system creates cleaner industrial wastewater prior to releasing it business while remaining a preferred newsprint supplier to the Green Bay Metropolitan Sewerage District. in the West,” said Allen Byrd, SPFT’s CEO. “Newberg is a Fox River Fiber said that it plans to sell the recovered biolog- solid asset with great people. We are very excited about this ical solids to other anaerobic treatment facilities for use as seed expansion of our packaging business in the West.” in treatment towers.

6 JANUARY/FEBRUARY 2014 PaperAge industry news

NORTH AMERICA Resolute to Indefinitely Shutdown the Last NPTA Presents 2014 Stanley O. Styles at Fort Frances Mill Industry Excellence Award to Don and Max Clampitt of Clampitt Paper Resolute Forest Products has The National Paper Trade Association announced the indefinite shutdown (NPTA) announced the recipients of its of the last operating paper machine 2014 Stanley O. Styles Industry Excellence at its mill in Fort Frances, Ontario Award — NPTA’s highest honor. For the by the end of January. first time in the award’s 30-year history, it The measure will, in effect, shut- will be presented to two industry leaders, down the entire mill. Don and Max Clampitt of Clampitt Paper. Some 150 workers will be Don Clampitt “Over the years, there are only a very impacted by the decision. few whose names are synonymous with the merchant and Late in November of 2012, Resolute shutdown the business. Clampitt is one of those rare names,” said mill at Fort Frances, which has an annual production capacity of Tom Gallager, President of West Linn Paper Company. “Max approximately 200,000 metric tons of market pulp, and PM5, Clampitt was a leader in every regard.” which has an annual capacity of 105,000 metric tons of ground- Max Clampitt was born in 1912 in Ruston, Louisiana and specialty printing . founded Clampitt Paper with his wife, Mary-Nell, in 1941. According to a CBC news report, Resolute attributed this lat- “Max Clampitt was a force in the merchant community,” est shutdown as the result of poor market conditions, although said James C. Tyrone, EVP of Commercial Operations and company president Richard Garneau said the paper machine will Business Development, NewPage Corporation. “He built a be kept ready for future operation. highly reputable and successful merchant business from the In the meantime the company said it is looking for alternative ground up. Don continued with the same focus on custom- products for its Fort Frances operation, especially related to the ers that Max did.” pulp mill. Don Clampitt began his 34-year career in the paper industry working in the warehouse of Clampitt Paper during RockTenn Acquires NPG to Expand Retail high school. He returned to the firm after graduating from the Innovation and Solutions University of New Mexico and since that time has worked in RockTenn in early-January acquired NPG, Inc., a leading inde- almost every position in the company. When Max passed pendent merchandising displays company. away in 2001, Don stepped into the President and CEO role. Headquartered in Chattanooga, Tennessee, NPG provides “In a time when paper is too often reduced to a com- a broad range of display products and services to many of the modity, Don still loves to talk about what makes paper, world’s most recognized retailers. NPG employs approximately particularly premium paper, unique,” said Tom O’Connor, 400 co-workers and operates two manufacturing facilities in Chairman and Chief Executive Officer of Mohawk. “He Chattanooga and one in Las Vegas, Nevada. pioneered the establishment of a Creative Center where “NPG’s focus on retailers, their innovative retail solutions designers and printers can come look at samples and talk and large-format printing capability expands our customer base about their work. Don is the only CEO of a major paper dis- and significantly improves RockTenn’s ability to provide retail tributor I know of who still loves to go out and teach paper insights, innovation and connectivity to all of our customers,” said classes for customers and design students.” Craig Gunckel, executive vice president, RockTenn, and general In addition to launching the Clampitt Creative Center in manager, RockTenn Merchandising Displays. 2004, Don has grown the Clampitt brand to include 15 retail NPG will operate as RockTenn Retail Solutions. stores and six warehouse locations and expanded to Tulsa, Phil Harris, formerly chief executive officer of NPG, has been Albuquerque and Kansas City. named vice president and general manager, RockTenn Retail Don Clampitt noted, “My father was the true visionary Solutions. Harris will continue to manage the operations along behind Clampitt Paper, and I am honored to be considered with his current leadership team. with him as a recipient of this award.” “NPG is a strong strategic fit for us that will strengthen our Don Clampitt will accept the Stanley O. Styles Industry display business,” said Steve Voorhees, RockTenn’s chief execu- Excellence Award on behalf of himself and Max at the tive officer. “I am excited to have the NPG team join RockTenn Paper2014 convention, March 23-25 in New York City. and look forward to supporting their continued success.”

PaperAge JANUARY/FEBRUARY 2014 7 industry news

NORTH AMERICA ASPI Recognizes Kapstone’s Paul Duncan FPInnovations and Kruger in Joint Project to with Excellence in Leadership Award Build Cellulose Filament Demonstration Plant The Association of Suppliers to the Paper FPInnovations and Kruger Inc. have announced a joint project Industry (ASPI) has named Paul Duncan to implement the world’s first five ton/day cellulose filament as the recipient of its 2014 Excellence in demonstration plant at Kruger’s Trois-Rivieres Paper Mill. Leadership Award. Duncan serves as mill The research and innovation project represents investments manager at KapStone Paper and Packaging’s totaling $43.1 million, including funding from Natural Resources Longview Mill in Longview, Washington, Canada, through the Investments in Forest Industry Transformation Paul Duncan where he is responsible for managing all of the (IFIT) Program, as well as a grant from the Quebec Ministry of manufacturing, maintenance and support operations of the mill. Natural Resources, a loan from Investissement Quebec, a con- “The Longview mill’s turnaround has been an incredible tribution from Kruger Inc. and funds from FPInnovations’ pulp, achievement for everyone involved, and Paul Duncan has been paper and bioproducts industrial members. a big part of that change,” said ASPI President Carl Howe, vice “A highly innovative wood-fiber based biomaterial, cellulose president sales for Kadant Paperline. “His professionalism, his filaments (CF) are expected to have an immediate impact on technical knowledge, and the example he sets for his employees Canada’s forest industry due to their capacity to be integrated all deserve to be recognized and applauded.” into other materials and to their high strength, light weight and As mill manager, Duncan played a critical role in the recent flexibility,” FPInnovations said. “CF will be used in a wide range transformation of the Longview mill, which resulted in a produc- of applications as a lightweight strengthening additive to pro- tion increase of 39% between 2007 and 2012. He also played a duce lower cost commercial pulps, papers, packaging, tissues and key role in improving the mill’s safety culture, and was named towels.” “Safety Manager of the Year” at the Western Pulp and Paper According to FPInnovations, the potential initial market for Workers Conference in 2012. CF as a strength reinforcing agent for traditional pulp and paper ASPI’s Excellence in Leadership Award honors unique and products is conservatively estimated at 120,000 tons per year in creative leadership of employees, company and key suppliers North America alone. In addition, a similar-sized, non-traditional through major projects or ongoing relationships. ASPI accepts market is forecast for thermoplastics, reinforced plastics, thermo- nominations from its members, and the Board of Directors votes sets, adhesives, and non-woven fabric and coatings, representing to determine the recipient. a total revenue potential of $500 million per year for companies Duncan is scheduled to accept the award at the ASPI 2014 that make use of CF. Spring Meeting, which will be held February 26-28, 2014 in Sarasota, Florida. INDIA Andhra Pradesh Paper Mills Changes Ahlstrom Completes Sale of Its West Name Carrollton Plant International Paper announced that the name of its group Ahlstrom has sold the converting operations of its West Carrollton company, The Andhra Pradesh Paper Mills Limited (APPM), plant in Ohio to West Carrollton Parchment and Converting Inc., has been changed to International Paper APPM Limited, an Ohio-based family-owned company. effective Dec. 16, 2013. The parties have agreed not to disclose the value of the deal. The company currently operates through two paper Under the terms of the deal, Ahlstrom sold its vegetable parchment converting assets and related order book to West mills at Rajahmundry and Kadiam in Andhra Pradesh under Carrollton Parchment and Converting. The approximately APPM’s name. 70 employees at the plant will transfer to West Carrollton “The new name recognizes the parentage of International Parchment and Converting. Paper while maintaining the link to the history of the As part of the sale, Ahlstrom and West Carrollton Parchment APPM brand,” explained Michael Amick Jr, President, IP and Converting will establish a long-term supply agreement India and Executive Chairman, International Paper APPM for vegetable , which is primarily used in food Limited. packaging.

8 JANUARY/FEBRUARY 2014 PaperAge industry news

EUROPE CEPI Director General Teresa Presas to Step Double A Agrees to Buy Pulp Mill in Alizay Down, Marco Mensink Named Successor Thailand-based pulp and paper producer Double A said that on After 10 years at the helm December 17 it agreed to acquire the pulp mill and bio-mass of CEPI, the Brussels- power plant that is situated next to the site of its Alizay paper based Confederation mill in France. of European Paper Terms of the deal were not disclosed. Industries, Teresa Presas Double A is buying the pulp mill from the Department of has decided to leave the Eure in Northern France. organization at the end of Jean Louis Destans, Chairman of the General Council of the Teresa Presas Marco Mensink May this year. In the com- region of Eure, said, “We have agreed on the selling price of the ing months she will ensure a smooth transition of the leadership land, the buildings and the assets necessary to revive the produc- of CEPI to her designated successor Marco Mensink, who has tion site. All that remains is for us to prepare and sign the deeds already worked with Presas as CEPI’s Deputy Director General as soon as possible. This is in both parties interest as it will initi- for the last two years. ate the revival of paper pulp production on the site.” Presas commented, “It has been ten years of an enriching On January 23, 2013, the Department of Eure bought the experience and of relentless work. In the last years, we have property and production assets of the Alizay pulp and paper mill consolidated our organization, successfully defended its interests site from Metsa Board for EUR 22 million. On the same day, the and laid out our long-term vision for the sector in the CEPI 2050 Department sold the paper mill to Double A for EUR 18 million. Roadmap. Double A said the investment in the pulp mill will also “The coming years will be about implementation at the include investment in the site’s bio-mass power plant. different levels, including the progression of the breakthrough Thirawit Leetavorn, Senior Executive Vice President of concepts that came out of the Two Team project. Therefore, it is Double A, noted, “2013 marked a successful return of the Alizay a good moment for me to leave the organization and move on to Paper Mill, which returned to full production in June and was another life. I wish my colleague and successor Marco Mensink producing premium quality Double A paper by August. The mill every success in the future,” Presas concluded. began exporting paper in September to the UAE and Eastern Domtar Completes Acquisition of Spain’s Indas Europe.” Double expects to restart the pulp mill in the first quarter of Domtar on Jan. 2 closed the acquisition of privately-held 2015. Laboratorios Indas, SAU (“Indas”), pursuant to a definitive agree- ment announced on November 19, 2013. SOUTH AMERICA Indas is Spain’s largest manufacturer and marketer of branded Suzano Starts Up New 1.5 Million TPY Pulp adult incontinence products, with its IncoPack and Indasec line Mill in Maranhao of products. Domtar acquired all the outstanding capital stock for EUR285 Suzano Papel E Celulose S.A. million and the business was expected to have about EUR140 recently started up operations million of debt, net of cash, at closing. Prior to the closing, at its new pulp production unit Domtar explained, “the net debt is expected to be reduced by located in Imperatriz, Maranhao, the collection of approximately EUR25 million of past due Brazil. accounts receivable before year-end or early 2014, resulting in The first bale of pulp was pro- an enterprise value of EUR400 million. The majority of the debt duced on December 30 with FSC certification, Suzano said. will be repaid by Domtar in connection with the closing of the The new pulp mill will have eucalyptus market pulp produc- transaction.” tion capacity of 1.5 million tons per year and surplus power John D. Williams, President and CEO of Domtar, commented, generation of 100 MW “The acquisition of Indas advances our transformation into a Suzano said mill personnel are now focused on effectively leader in Personal Care, an attractive market segment that is executing the ramp-up period to ensure an adequate learning an important growth engine for Domtar. With the addition of curve. the new business, Domtar will become one of the leading adult Suzano expects the pulp mill to produce about 1.1 million incontinence products manufacturers in Europe.” tons in 2014.

PaperAge JANUARY/FEBRUARY 2014 9 industry news

SOUTH AMERICA Fibria Continues Feasibility Studies on INDUSTRY SUPPLIERS Expansion of Tres Lagoas Pulp Mill Minerals Technologies to Build Satellite Fibria announced that it is PCC Plant for UPM in China continuing with the feasibil- Minerals Technologies has signed an agreement with UPM ity studies for the expan- to build a satellite precipitated calcium carbonate (PCC) sion of its pulp mill in Tres plant on-site at UPM’s paper mill in Changshu, China, Lagoas (Mato Grosso do Sul located in Jiangsu province. The satellite plant will provide State), Brazil. The company PCC — a specialty pigment for filling and coating high- met with approximately 150 quality paper — to the mill and have an initial capacity of representatives of the main 100,000 short tons. 36 equipment supplier com- “We are extremely pleased that UPM, a premier global panies of the pulp industry in the interior of São Paulo state. papermaker, has chosen Minerals Technologies’ PCC for “The idea behind the meeting was to invite [the representa- their paper-filling needs at their mill in Changshu,” said tives] to participate in the detailing stage of the project, which Robert S. Wetherbee, CEO of Minerals Technology. “This should be submitted to the approval of the Board of Directors by is our fourth satellite agreement in China within approxi- the end of the first half of this year,” Fibria explained. mately one year, bringing our total to seven in that country.” Fibria’s new pulp line in Tres Lagoas, which already has The plant is scheduled to begin operation early in 2015. environmental licensing, and, if installed, will have a capacity 1.75 million tons per year, would increase the mill’s total pulp Wuhan Chenming Starts Up Valmet- production capacity to 3.05 million tons per year, making it the supplied Tissue Line in China largest pulp industrial unit in the world. A new tissue line Fibria said that it is making every effort to take advantage of delivered by Valmet a window of opportunity for the start-up of its new pulp capac- (formerly Metso ity, and that it already has a major portion of the wood supply Pulp, Paper and needed for the new plant’s operations. Power) successfully Fibria expects the new line to begin operations at the end of came on stream at the fourth quarter of 2016. Wuhan Chenming The Tres Lagoas mill opened on March 30 2009 and has a Hanyang Paper Co. bleached eucalyptus kraft (BEK) pulp production capacity of 1.3 Ltd’s mill in Wuhan, China, in November 2013. This is the million tons per year. The mill is self-sufficient in energy, using customer’s first tissue line, Valmet said. biomass from eucalyptus and black liquor used in the industrial According to Valmet, the new Advantage DCT 200HS process. tissue line started up ten days before the estimated time and is now producing high quality tissue at high speed. With a Norske Skog and CellMark Agree to Paper width of 5.6 meters and an operating speed of 1,900 m/min, Distribution Deal in Asia the new production line will produce 60,000 tons a year of Norske Skog and CellMark AB have entered a long term mar- high-quality facial, toilet and towel grades. keting agreement for sales of publication paper in the Asian The raw material for the new line is virgin pulp, markets and established a new distributor in Singapore, NorCell Valmet said. Asia, which holds exclusive marketing rights for all Norske Skog The delivery comprised a complete production line with products to be sold in the Asian markets. stock preparation equipment and an Advantage DCT 200 Norske Skog is transferring its current sales operations and HS tissue machine including an OptiFlo II TIS multi-layer sales staff in Singapore from PanAsia Paper Trading to NorCell headbox, a cast alloy Yankee cylinder, an Advantage AirCap Asia. hood, an Advantage WetDust dust management system and Norske Skog plans to release about USD 15-20 million in an Advantage SoftReel reel. working capital by the cooperation with CellMark in the Asian The delivery also featured Valmet’s patented Advantage markets. ViscoNip pressing technology.

10 JANUARY/FEBRUARY 2014 PaperAge industry news

India’s Printers at Odds with Paper Producers’ Price Hikes India’s paper and board manufacturers in 2013 pushed through substantial price hikes that they say were necessary to offset ris- ing input costs, while the region’s printers have watched their profit margins shrink to unacceptable levels. According to a report in PrintWeek (India), paper and board producers in fiscal 2013 increased prices by 10 – 15%, and some cases as much as 20 – 30%. The papermakers attribute the price hikes to the increasing cost of domestic wood as well as imported materials such as pulp and coal, due to Rupee’s depreciation. “Paper mills are importing pulp wood, even if it is costlier Paper2014 to be held at the by 30 - 40%, as domestic stocks are scanty. JK Papers cites the New York Palace Hotel, March 23-25 reason for this to be a disease outbreak that hit tree plantations The American Forest & Paper Association (AF&PA) and in Andhra Pradesh three years ago; and because of this, the NPTA Alliance announced that Paper2014 will be held at gross tonnage of wood availability has taken a nosedive. Though the New York Palace Hotel, March 23-25, 2014. companies have stepped up farm forestry, it will take another Paper2014 is the premier annual paper industry couple of years before normalcy can be restored,” explains Anand business convention, providing leading executives from Srinivasan, author of the PrintWeek report. across the industry with engaging sessions and unparal- In addition, India’s papermakers will have to deal with a leled networking opportunities. reduction on import duties in 2014. “The domestic paper indus- The New York Palace, located on Madison Avenue, try, which is struggling to cope with high input costs and chronic is newly renovated and will provide a stunning venue for shortage of wood pulp, will face a new challenge in 2014 – duty- networking in addition to being convenient to Midtown free import of paper from Southeast Asian countries,” said Anand Manhattan restaurants and attractions. Srinivasan, author of the PrintWeek report. Paper2014 and the New York Palace offers: However, India’s printers are unsympathetic and say the fre- • Single location for meetings and programming that will quent price increases come without warning. In an open letter maximize networking opportunities to the chairman of the Competition Commission of India (CCI) • New for 2014! – Larger Tower Corner suite option is more than twice the size as previous hotels for in New Delhi, the Sivakasi Master Printers’ Association (SMPA) entertaining up to 50 people. called on CCI to take action against the paper mills that would • Best space, most amenities, with the greatest value stop what has been termed “unfair trade practice” and substan- for rooms and suites in midtown tially reduce the arbitrarily increased prices, as well as to direct • New for 2014! – Complimentary WiFi in guest rooms the mills to maintain prices at least for a period of four months. and suites “The print industry needs to be protected from the clutches • New for 2014! – Dedicated hotel banquet staff to of paper mills which are into the process of making print indus- service your meeting needs try a scapegoat at the altar of price increase, leading to the ques- Paper2014 Suites tion of survival in the future,” SMPA wrote. Official Paper2014 Suite holders will maximize visibility Domestic printers point out that many have annual contracts and strengthen relationships with customers, suppliers, with their customers and are unable to pass along the increases. manufacturers, publishers and distributors of printing “The price has increased twice or thrice in the last two quarters paper, packaging material and industry suppliers. of 2013, taking the landed prices up by 20–30%. It has hit the Pre-reserve Your Suite Today bottom line, as the cost cannot be passed on to the customers in Suites sell fast and are being offered on a first come, first near terms,” said Vasant Goel, Director, Gopsons Papers, one of served basis. Take advantage of this great value before India’s largest integrated print houses. all suites are sold by contacting Nicole Boland by email For now, Srinivasan says, many printers are resorting to buying at: [email protected] or call (312) 673-5828. from cheaper mills or considering importing paper stocks despite Paper2014 is hosted by the American Forest & Paper the Rupee’s depreciation. Association and NPTA.

PaperAge JANUARY/FEBRUARY 2014 11 people

PAPER

n Ahlstrom announced that Sakari Ahdekivi n Twin Rivers Paper Company announced that Tony has been appointed Chief Financial Rigelman has joined the company as Vice President, Sales. Officer and member of the company’s Rigelman has over 19 years of industry experience in a Executive Management Team. He will variety of leadership roles, serving most recently as Director join Ahlstrom on February 1. Prior to of Sales for Technical and Specialty Papers at Domtar. Ahlstrom, Ahdekivi was Managing Director at Tamro Finland and Baltics. Sakari Ahdekivi INDUSTRY SUPPLIERS

n Appvion announced that n Ashland Water Technologies has hired Matt Denton has been Jeff Fulgham as vice president, market- appointed Senior Vice ing. He most recently served as chief President and General sales and strategy officer for Banyan Manager of the com- Water, based in San Francisco. pany’s carbonless and n OASIS Alignment Services has named Jeff Fulgham security papers business; Matt Denton Jason Schulist Brian J. Hiltunen as President. He and Jason Schulist has joined Appvion as Vice President succeeds Ray Masse, who will continue of Continuous Improvement. as Chairman of the Board. Previously, n Atlas Paper Mills has named Jim Brown as Chief Hiltunen served as Vice President and Executive Officer. Brown succeeds Joe Tadeo, who left General Manager for OASIS. the company to pursue outside interests. Brown most n Thiele Kaolin Company recently Brian Hiltunen recently served as an Executive Vice President at Duro announced the following changes within Bag Manufacturing Company. its sales leadership: Eric Tillirson has been promoted to n Greif has appointed Peter Watson as Senior Vice President and Director of Sales Development; Chief Operating Officer of the company. Mike Markillie has been promoted to Director of World Watson was group president responsible Wide Sales and Technical Service; Scott Ahrens has for Greif’s Paper Packaging and Land been promoted to North American Sales Manager; and Management business segments as well Tom Bennett has been promoted to Sales and Marketing as Global Sourcing & Supply Chain and Manager. the company’s Greif Business System Peter Watson INDUSTRY-RELATED capabilities.

n Mac Papers has named Craig Boortz as the new Vice n The Confederation of European Paper President and Regional Manager. He succeeds Steve Bethea, Industries (CEPI) has appointed Gary who is retiring after more than 42 years with the company. McGann as its new Chairman. McGann In a related move, David McGehee, Jr., succeeds Boortz’s as is Group CEO of Smurfit Kappa. He General Manager in Greenville, SC. succeeds outgoing chairman, Jussi Pesonen, the President and CEO of UPM. n PaperWorks Industries has named William McSwain as Gary McGann n University of Maine alumna Carrie Enos interim President and CEO, replacing Mark Staton, who has been named president of the departed in January. McSwain is a seasoned business University of Maine Pulp & Paper executive with leadership experience in many industries. Foundation. She replaces Jack Healy ‘74, n Rayonier has elected Lynn Wilson to the position of who has held the position since 2007 Executive Vice President, Forest Resources. Wilson is a and is retiring this spring. Enos has member of Rayonier’s senior management team and is worked in the paper industry since 1997, Carrie Enos responsible for 2.6 million acres of timberland in nine most recently in the position of finished products business states and New Zealand. unit manager at the Verso Paper Mill in Bucksport.

12 JANUARY/FEBRUARY 2014 PaperAge calendar

FEBRUARY 3-6, 2014 JUNE 3-5, 2014 June 22-26, 2014 Paper Week Canada - 100th Anniversary PulPaper 2014 60th IEEE PAPTAC Adforum Conference Fairmont Queen Elizabeth Hotel Helsinki Exhibition & Convention Centre Institute of Electrical and Electronics Montreal, Canada Helsinki, Finland Engineers www.paperweekcanada.ca/ www.pulpaperevent.com Atlanta Marriott Buckhead Hotel Atlanta, Georgia, USA June 22-25, 2014 FEBRUARY 11-12, 2014 www.ieee.org Forest Products Investment Conference 71st Pulp and Paper Safety Conference RISI Pulp and Paper Safety Association Grand Hyatt New York Renaissance Vinoy Resort New York, New York, USA St. Petersburg, Florida, USA www.risiinfo.com/events www.ppsa.org

FEBRUARY 26-28, 2014 ASPI Spring Meeting Association of Suppliers to the Paper Industry Ritz-Carlton Tough little cookies. Sarasota, Florida, USA www.aspinet.org A crushed roll of paper can cost manufacturers and their customers countless MARCH 18-21, 2014 hours, dollars, and headaches. But by simply inserting core plugs into each roll, Tissue World Americas paper makers can reduce damage and loss claims for just pennies per roll. As a family-owned New England company that has been producing core plugs UBM Asia Trade Fairs for over 50 years, Souhegan guarantees a high-quality, steady inventory of the Miami Beach Convention Center products you need, whenever you need them. Miami, Florida, USA www.tissueworld.com We offer two different types of high-density, molded wood core plugs engineered specifically for the paper industry: MARCH 23-25, 2014 Paper2014 AF&PA and NPTA New York Palace Hotel New York City, New York, USA Contact: Nicole Boland (NPTA) [email protected]

APRIL 2-4, 2014 Spring Outlook and Strategies Conference Paperboard Packaging Council Royal Sonesta Hotel New Orleans, Louisiana, USA www.ppcnet.org

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PaperAge JANUARY/FEBRUARY 2014 13 market grade Capacity Bulge, Sluggish Demand Remain Challenges for Containerboard Market 2013 wasn’t a bad year for containerboard mills but results were decidedly mixed. Price increases were enacted on board and corrugated boxes in early 2013 that boosted margins, but underlying box demand was stagnant. 2014 offers hope that improved economic growth can propel box demand to stronger gains, but the impact of new containerboard capacity remains a nagging concern.

By Harold M. Cody

ver the course of the OCC costs and a long term last 12 months the over supply situation in the Ocontainerboard indus- box market. The increase try was characterized by was successful mainly due to relatively weak fundamen- the sweat and hard work on tal demand for corrugated the part of board producers containers and rising capac- who took significant market- ity. However, despite these related downtime to keep negative trends, the overall inventories under control business benefitted from an and the market balanced. approximate $100/ton price At the end of the year and increase in major container- into early 2014, prices are board grades and an increase reported to have held mainly in box prices as well. The steady despite somewhat biggest concern entering weak box cut ups during the 2014, other than the basic seasonally slow months of strength of the global econ- Significant new capacity came online in the the year again due to down- omy, is the impact of a surge second half of 2013. This includes tonnage time that sustained operating in new capacity, which could from the startup of Norampac’s new 330-inch, rates. throw a monkey wrench into 525,000 tpy recycled linerboard machine at the As noted, OCC costs fell the works. Greenpac mill in Niagara Falls, New York. steadily from a peak almost The rise in prices and a $180/ton in late 2011 before muting of input costs — at least for a while as OCC prices bottoming out at about $100/ton in early 2013. Since then, fell to very low levels earlier in 2013 — were certainly prices have posted a modest rebound but remain low. Many noteworthy developments last year in the containerboard observers believe that as global containerboard demand market. In April, a $50/ton increase was successfully passed accelerates in 2014, OCC prices will surge and this may pro- on to converters that raised linerboard prices to about the vide the impetus for prices to also rise further on liner and $650/ton range. This was the second successful increase in medium grades this year. an eight-month period, following a $50/ton increase that U.S. box and containerboard data through November was enacted in September 2012. These increases signific- 2013 clearly demonstrate the impact of sluggish economic, antly improved operating margins for the major producers. job and personal income growth on the box market. For the Containerboard mills were able to push through the first 11 months of 2013, box shipments were down 0.5% increases despite several important indicators that wouldn’t vs. the prior year at 331.2 billion square feet year-to-date, seem to support an upward movement in prices, i.e. weak and down 2.5% vs. November 2012 levels. On an average domestic demand for corrugated boxes, a steady decline on week basis, which accounts for a different number of ship-

14 JANUARY/FEBRUARY 2014 PaperAge market grade ping days month to month, November box shipments were Box Demand and Consumer Spending up 2.6%, according to FBA and AFPA data. Total contain- Probably the biggest unknown in the outlook for contain- erboard production, at 31.9 million tons, was up 1.6% over erboard is box demand. The reasons behind the relatively the first eleven months vs. the prior year level, but down poor performance recently in box demand is fairly obvi- 4.5% in November vs. last year. ous: a sluggish U.S. economy in combination with weak job Export Markets Cooled in 2013 growth and poor growth in personal income resulted in The export market continues to be an important market for weak growth in consumer spending. This is particularly true U.S. mills, with linerboard exports through November at for key markets that consume a lot of corrugated board such 3.5 million tons according to AF&PA. However, this is down as food and beverage. With sluggish or no growth in dispos- 0.6% vs. 2012 levels. While demand in some export markets able income over the last few years, consumers spent less on has weakened the drop is also partly due to mills in North packaged food and beverages. These uses are critical for box America diverting tonnage to domestic markets. The export plants as they account for just under half of total U.S. box market has appeared to be weak in recent months, with shipments. Major food companies also reported lackluster export prices reported to be down in Europe and weak in results, mirroring the poor performance of corrugated boxes. Latin America. The weaker pricing is a result of a slowdown Looking Ahead in demand plus an excess of supply in several regions includ- Looking forward into 2014, there is hope that the U.S. and ing North America and Europe. European economies will perform better than they did in U.S. Bureau of Census data through the first three quar- 2013, and this could provide a modest boost in box demand. ters of 2013 showed U.S. Kraft linerboard exports down Many economists believe that the U.S. economy could 6.3% at 2.8 million tons vs. the same period in 2012. expand at closer to a 4% rate this year vs. weaker growth Exports to the largest U.S. export market, Western Europe, pegged at about 3% in 2013, which is coming on the heels were off nearly 20% at 585,000 tons. Exports were also of 2.8% and 1.8% growth in GDP in 2011 and 2012, respec- down significantly to Canada, while smaller drops were tively. Similarly, Europe’s GDP fell in 2012 and was expect- posted for Mexico, the Middle East and Africa. In contrast, ed to post little or no gain in 2013. However, projections exports to Central America and South America, at 438,000 call for modest growth in the Euro area economy in 2014. tons and 439,000, were up by 3.6% and 11%, respectively, Notable structural changes in the containerboard mar- vs. 2012 levels. In turn, export prices are reported to have ket in recent years, and which continued in 2013, will also slipped as well in Europe and were under pressure in the likely impact the market’s supply and demand balance as fourth quarter in Latin America. well as the direction of pricing. Major mergers and acqui- New Capacity a Concern sitions, including two major ones in 2013, have resulted As noted, significant new capacity came online in the sec- in the top five containerboard producers now accounting ond half of 2013 that is a cause for concern, but report- for 75% of U.S. capacity. The most recent deals closed last edly, so far, it hasn’t had a severe impact on the market. year include Kapstone’s $1 billion acquisition of Longview This includes tonnage from the startup of Norampac’s Fibre and PCA’s $2 billion acquisition of Boise. Kapstone’s new 330-inch, 525,000 tpy recycled linerboard machine deal moved the company into the No. 5 position in North at the Greenpac mill in Niagara Falls, New York and the American containerboard capacity, behind International conversion of two newsprint machines to containerboard. Paper, RockTenn, Georgia-Pacific and PCA. This includes the addition of 150,000 tpy of linerboard by A rebound in the U.S. economy and thus improved SP Fiber in Dublin, Georgia, and 300,000 tpy by Atlantic box demand would be of great benefit to producers, who Packaging in Whitby, Ontario. wouldn’t have to continue to take downtime and also would The converted paper machine in Dublin has a 390,000 result in higher operating rates. It would also go a long way tpy capacity, but the net gain is 150,000 tpy because of in accommodating the recent capacity that has been added switching another machine at the mill from board to news- and allow producers to maintain a more balanced market. print. Combined, the new machine and conversions added Given the recent weakness and new capacity it’s unlikely any nearly one million tons of new capacity. All three machines major movement in prices can be expected early this year. came online in the 2nd and 3rd quarter of 2103. The impact However, if the U.S. and global economy improves, and of this tonnage, much of which was just beginning to hit the input costs such as for OCC begin rising, producers are market late in 2013, is a major concern in 2014. Pratt also likely to seek additional increases later in 2014. n announced plans to build a 360,000 tpy containerboard mill Harold Cody is a contributing writer for PaperAge. He can be by its box plant in Valparaiso, Indiana. reached by email at: [email protected]. PaperAge JANUARY/FEBRUARY 2014 15 heads up Quiet Start in Europe The European paper industry is off to a relatively quiet start in 2014, and industry observers say the year may continue as such, which may be a good thing.

By David Price

t’s hard to spot unless industry. The consequences you’re a chemist in an could have been devastating. Iindustry lab, where there’s in Europe a lot happening in cellulose would have dropped from 47 and nanotechnology. Or if you million tpy to 37 million tpy, build with wood you’re doing leading to mill closures and the well here in Europe. I con- disappearance of hundreds of tacted the top five European recycling operators. pulp and paper companies, In a symbolic act in spoke with two consultants, September 2013, CEPI tempo- and attended two major con- rarily dumped bales of waste- ferences (Hawkins Wright paper in front of the EU’s and European PaperWeek). headquarters in Brussels to The conclusion: not a lot is draw attention to the problem. happening. Yes, Domtar just Waste paper or recycled? In September 2013, So now it’s back to the draw- completed its acquisition of CEPI temporarily dumped bales of waste paper in ing board to try and solve the the Spanish personal care front of the European Commission’s headquarters problem of when does paper products manufacturer Indas, building in Brussels to draw attention to the cease to be classified as waste? and Double A of Thailand EC’s proposal to redefine recycled paper. It so happens that, at pres- (formerly Advance-Agro) has ent in Europe, sourcing good announced plans to restart the Alizay pulp mill that sits next quality recycled fiber is becoming a problem, especially for its paper mill in France, but that’s about it. the tissue sector. Bits and Pieces Paper or Plastic? Yet there is some significant and positive action in recy- The Bank of England (BoE) has decided to replace British cling, security papers and tissue. The industry has success- bank notes with plastic (polymer) notes. The job was fully lobbied the European Parliament to block a proposal expected to go to either De La Rue, the existing maker by the EU to reclassify wastepaper — the vote was 606 of BoE notes, or Innovia, which manufactures most of the “for” and 77 “against.” This proposal would have classified polymer notes around the world. The Bank promised a con- wastepaper as “recycled” even before it’s been recycled! The sultation process last October but by January it was a done vote in Strasbourg will save more than 20,000 ‘green’ jobs deal with Innovia. The Bank has ruled out importing plastic in the industry and 140,000 indirect jobs in Europe. If this money from China. legislation had passed it would have relaxed the EU’s waste Mark Carney, formerly the Governor of the Bank of management rules and triggered a flight of wastepaper from Canada, is now Governor of the BoE. While Governor of the EU to Asia, pushing up prices in Europe and undermin- the Bank of Canada he introduced in 2011 a change of ing the quality of wastepaper available to the EU recycling paper to plastic for $100 bills. Canada has since gradually

16 JANUARY/FEBRUARY 2014 PaperAge heads up

switched to plastic $50, $20, $10 and $5 bills. Pampers (P&G), which dominates the UK market, have They say a plastic bank note is tougher to counterfeit, fallen by 4.1% according to the trade magazine The Grocer. lasts longer and can be cleaned. But I also hear that vend- The UK diaper market is worth $800 million a year and ing machines must be upgraded in order to accept them. Pampers sold 76.3 million fewer diapers last year despite its Bottom line: the Bank of Canada says they’re here to stay. If biggest rival, Huggies (Kimberly-Clark), exiting the UK and this is the future of bank notes in the UK, what will happen European market last October. K-C’s shock exit closed mills to the traditional British printers and producers of security in UK, Italy, Spain and Poland with the loss of 1500 jobs. papers? It will be a massive blow said one manufacturer Consultants think the drop in sales is due to middle class who did not want to be named. A consultant to the industry households doing their bit for the environment and families told me it will be a big hit on this specialist sector, but it switching from the big brands to cheaper diapers from the will survive as De La Rue and others are major suppliers of discount retailers as household budgets shrink. Own-label paper bank notes to countries all over the world. products are up by 37.3% and volume sales have risen 44.5% The money and ownership trail of Innnovia is fascinat- But P&G, SCA and the Italians — with 7 million tpy of tis- ing. It is an off-shore company and its owners plan to sell sue production in Europe — seem unfazed by this trend. it to Pamplona Capital Management, a fund backed by the I’m not convinced there’s a long term market for reusable Russian billionaire, Mikhail Fridman. The Guardian news- diapers. I think it’s fashionable and green and will not last. paper commented, “If the Bank thinks it unacceptable for If you think through the detail of cleaning, separating and British currency to be in Chinese hands, are Russian hands reusing a soiled diaper, the technical and hygienic issues are any more acceptable?” considerable. And there is solid evidence the tissue makers are rethinking their use of recycled fiber in their products Reusable Diapers and are turning, increasingly, to virgin fiber. n Despite the biggest baby boom in the UK in 40 years, sales of diapers have fallen nearly 4% in the last year. Sales of David Price is a contributing writer for PaperAge. He can be reached by email at: [email protected]. EASY OPEN ... EASY CLOSE

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PaperAge JANUARY/FEBRUARY 2014 17 Easy-to-Apply Dryer Performance Indicators

Photo courtesy of Kadant Johnson Inc.

The dryer section is a large consumer of energy, but ensuring it is operating efficiently is not difficult. By assessing only a few easily applied “dryer performance indicators”, one can determine whether large improvement opportunity exists.

By Jeff Chaloux

ryer performance audits have been used for years as • High pressure motive steam consumption as a percent of part of efforts to optimize the papermaking process. total dryer section steam consumption DThese audits involve quantifying dryer performance Commonly applied standards for these indicators, the indicators and comparing the indicators to performance reasoning behind the standards, and considerations related standards. Some of the traditional indicators are not easily to assessing the indicators are highlighted the following applied since they require special measurement techniques discussion. and a highly experienced assessor. Others are easily applied HOOD EXHAUST HUMIDITY and are valuable to optimization efforts. Five easily applied dryer performance indicators that TAPPI standards specify the exhaust air drawn from the provide a good indication of dryer section energy efficiency dryer section hood be 0.04 to 0.07 kg w.v./kg d.a. (300 to include: 500 grains) for “open” type hoods, 0.13 kg w.v./kg d.a. (900 grains) for “medium humidity” closed type hoods with fully • Hood exhaust humidity enclosed basements, and 0.17 kg w.v./kg d.a. (1200 grains) • Dryer section supply air flow relative to dryer section for “high humidity” closed type hoods. Operating a hood evaporation load with excess exhaust (and too low a humidity) lowers the air • Dryer section supply air temperature temperature surrounding the sheet, dryers, and dryer fabrics. • Energy losses from the steam system relative to total It also increases the radiation and convection heat losses steam dryer steam consumption and reduces the effectiveness of heat recovery equipment

18 JANUARY/FEBRUARY 2014 PaperAge energy efficiency – dryer section installed on the hood exhaust sys- Machine Production Rate (Metric TPD) tems. Operating a hood with insuf- 0.250 Open Hoods ficient exhaust positively impacts 0.225 Closed Hoods energy efficiency, but it risks opera- 0.200 HIgh Performance Hoods Recommended for High tional problems such as dripping on Performance Hoods

./kg d.a.) 0.175 the sheet, corrosion of equipment, v and spillage of heat and humidity 0.150 to the machine room. 0.125 Hood exhaust humidity can eas- Recommended for Closed Hoods 0.100 ily be assessed by inserting a wet and dry bulb thermometer into 0.075 Exhaust Humidity (kg w. g.

the hood exhaust flow stream. For Av 0.050 an accurate measurement of wet Recommended Range for Open Hoods 0.025 bulb temperature, the air velocity passing across the wet bulb should 0.000 be greater than 3 m/s. Many dryer 0 500 1000 1500 2000 sections operate with inappropriate Figure 1 – Measured Average Hood Exhaust Humidities on Active Paper Machines amounts of exhaust. Figure 1 shows (See TAPPI TIP 0404-24 for guidelines on calculating the average hood exhaust humidities for several recently evaporation load.) The total supply air flow rate to the dryer measured operating paper machines. section should be assessed with field measurements. For DRYER SECTION SUPPLY AIR FLOW RELATIVE TO most hot air supply systems, the best method for measuring EVAPORATION LOAD flow rate involves using a vane anemometer at the face of The rate of hot air supply to the dryer section should be air intakes. appropriate for the rate of evaporation from the dryer sec- DRYER SECTION SUPPLY AIR TEMPERATURE tion. If it is not, there is opportunity to save energy or Assessing supply air temperatures for pocket ventilation improve drying performance. systems is normally easy. If online indication does not exist, Most paper machines are operated with a heated supply temperatures can be easily measured with a thermocouple air system serving the dryer section. The delivery of heated probe inserted into the supply air stream. The TAPPI rec- supply air to the dryer section lowers the relative humidity ommended supply air temperature for dryer section supply of air surrounding the sheet and drying equipment. Nearly air systems is 82 to 93°C. Temperatures significantly lower all dryer sections that operate with no form of dryer section than this range are usually inappropriate since they increase supply air system are unfelted dryer sections that lack felt risk of condensation, dripping, and corrosion of equipment. rolls. On dryer sections with dryer fabrics, having heated Temperatures significantly above this range are usually supply air is normally necessary to avoid felt roll corrosion. inappropriate since they significantly increase energy TAPPI standards specify pocket air humidity be between demand while providing little benefit. 0.12 to 0.28 kg w.v./kg d.a. For high-speed machines making lightweight grades, excessive air supply to dryer pockets can ENERGY LOSSES FROM THE STEAM SYSTEM negatively affect web stability. For machines that do not An energy efficient steam system operates with few losses. have problems with sheet flutter, it is suggested the air sup- By far, the easiest way to assess the energy efficiency of a ply to the dryer section target a humidity of 0.20 kg w.v./ steam and condensate system is to quantify steam losses kg d.a., which is the median of the recommended humid- from the system and compare them to total dryer section ity range by TAPPI. To achieve this pocket humidity, the steam consumption. Alternative methods of assessing steam amount of air that must flow into the dryer pocket is 4.2 kg system energy efficiency, which include evaluating steam d.a./kg evaporation. consumption per unit evaporation or steam consumption To assess the supply air flow rate per unit evaporation, per unit production, have clear shortcomings. Realize that both the dryer section evaporation load and the total supply the waste steam flows that hurt steam system energy effi- air flow rate must be assessed. The dryer section evaporation ciency are normally small relative to total dryer section load can be quantified with a simple drying rate calculation. steam consumption. When quantifying steam consumption

PaperAge JANUARY/FEBRUARY 2014 19 energy efficiency – dryer section

Dryer Performance Indicator Recommended Level let water piping, and to then measure the line temperature Hood exhaust humidity 0.04 to 0.07 kg w.v./kg d.a. with an infrared pyrometer. for an “open” hood Flash steam losses from Main Condensate Tank. A good 0.13 kg w.v./kg d.a. for a steam system is designed such that flash steam generated at medium humidity closed hood a main condensate collection tank is put to good use. Flash 0.17 kg w.v./kg d.a. for a steam losses to atmosphere should be completely avoided. high humidity closed hood The best use of low-pressure flash steam is for any cylinders Dryer section supply air flow 5 to 7 kg d.a./kg w.v. relative to dryer section being operated at low pressure. Another potential good evaporation load use for flash steam is at pocket ventilation supply units Dryer section supply air 82 to 93°C equipped with flash steam coils. Yet another potential good temperature use for flash steam is at steam showers or steam boxes. If Energy losses from the steam Total combined steam losses flash is used for steam showers and steam boxes, appropriate system relative to total steam less than 3% of total dryer dryer steam consumption section steam consumption safeguards against condensate carry-over must be applied. A High-pressure motive steam 4 to 8% of total dryer section realistic goal is to have no flash steam losses to atmosphere. consumption as a percent of steam consumption HIGH PRESSURE MOTIVE STEAM CONSUMPTION total dryer section steam consumption A common type of steam system for paper machine dryer sections is a thermocompressor type system. This system uses per unit evaporation, highly accurate information on steam high-pressure motive steam for recompressing blow-through consumption and evaporation load are needed just to get a steam. For those mills that have steam-driven turbine gener- rough indication of steam system energy efficiency. ators, high-pressure steam is more valuable than turbine An energy efficient steam and condensate system will exhaust steam. The high-pressure steam can be passed have total “losses” that equate to less than 3% of total dryer through the turbine generator so that relatively inexpensive section steam consumption. Following are the most prevalent thermal energy is converted to a more valuable electrical forms of energy losses from a steam and condensate system. energy. For mills with turbine generators, the paper machine Venting from steam sections through automatic vent dryer section should draw as high a percentage as possible valves. A well-designed steam system with properly func- of its total steam demand from headers being fed by turbine tioning devices will vent no steam during “sheet on” condi- exhaust and as little a percentage as possible from headers tions. Open vent valves during “sheet on” conditions gener- being fed high-pressure steam that has not passed through ally indicate a steam system deficiency or equipment prob- turbine generators, or has only partially passed through lem. If venting is occurring, the recommended technique turbine generators to an intermediate extraction point. for quantifying the steam lost is a simple steam valve flow Potential methods for reducing motive steam consump- calculation. tion include: Steam losses to a condenser. Paper machine dryer sec- • Replacing inefficient thermocompressors with properly tions with cylinders operating at low pressure are equipped sized high-efficiency units. with one or more vacuum condensers. When assessing steam system energy efficiency, the steam energy losses to the con- • Upgrading rotary syphons to stationary syphons denser are viewed as waste. This is even for cases where the • Improving the accuracy of differential pressure transmit- warm water from the condenser appears to be fully utilized. ters so that differentials can be minimized. For most paper machines there is potential to either reduce • Actively managing differential pressures as a function of the demand for warm water or to generate the required machine operating conditions so that excessive differ- warm water using a form of heat recovery. ential pressures are avoided. This is best done through The best technique for quantifying the steam energy application of supervisory control logic. losses to a condenser measures the water flow rate with a The dryer section is a large consumer of energy, but ensur- portable water flow meter and the inlet and outlet water ing it is operating efficiently is not difficult. By assessing only temperature. Modern “transient time” meters are well a few easily applied “dryer performance indicators”, one can proven for the suggested water flow measurement. An easy determine whether large improvement opportunity exists. n method for assessing water inlet and outlet temperature is to Jeff Chaloux is a Senior Process Engineer for Kadant Johnson paint black “spots” on uninsulated portions of inlet and out- Systems Division. He can be reached at: [email protected].

20 JANUARY/FEBRUARY 2014 PaperAge PAPER Convention Daily

MONDAY, MA RCH 18, 2013 Schedule of Events Opportunities Abound in Chicago PAPER (all meetings and events are being held at the Fairmont Chicago) This year’s program MOndAy, MARch 18, 2013 focuses on the opportunities kets, and business and demographic Convention Daily in emerging markets, and trends that affect the paper and • 7:00 a.m. – 5:30 p.m. pa- Paper2013 Registration business and demographic per-based packaging industry. Paper2013 Convention Over the next two days, compan trends that affect the paper y TUESDAY, MARCH 19, 2013 Daily Desks suites are open so we can check in David Scheible, P’13 Lounge Don Clampitt, and paper-based Chairman, AF&PA with key clients and suppliers an Schedule of Events Moulin Rouge Room, Lobb Chairman, NPTA d packaging industry. connect with existing and poten (all meetings and events are being hel 17, 2013 y Level On behalf of the American tial at the Fairmont Chicago) PAPER • 8:00 a.m. – 4:00 p.m. Forest & new business contacts. portunities. Paper2013 will provide Preserving Paper as Part of Federal Information Policy Official Hospitality Suites Open Paper Association (AF&PA) and th Thank you for joining us at Paper- d e a number of opportunities to gain TUESday, March 19, 2013 The federal government is increas- • 10:30 – 11:00 a.m. NPTA Alliance, we are hon 2013. We look forward to sharing the paper-based packaging industry. ored to new perspectives, share insights and • 8:00 a.m. – 4:00 p.m. ingly pushing Americans into digi- Paper Check-off Information welcome you to Paper2013. experience with you. During the Luncheon, David S. network with fellow paper industry Paper2013 Registration tal-only information delive Session This annual event is where our Convention Daily David Scheible is President & CEO of Paper2013 Convention vate sector,” says AF&PA Pr McGehee of Mac Papers will be pre- “Investing in our Future – industry meets. This year in Chi- executives. without regard to how these policies PA Daily Desks and CEO Donna Harman. “And in SUNDAY, MARCH sented with the NPTA Stanley O. The Paper Check-off” This year’s program focuse Graphic Packaging International, Inc.; affect key demographic groups,ry, often ce industry, providing their perspec- cago, the theme is Passport to O s on and Don Clampitt is CEO, Clampitt P’13 Lounge this case, the federal governmentesident President & CEO, AF& Styles Industry Excellence Award. (open to all Paper2013 regist p- the opportunities in emer cluding senior citizens, non Welcome to Paper2013tives on emerging issues, trends and rants) ging mar- Paper Company. Moulin Rouge Room, Lobby Level No more paper savings bonds nley, CEO, NPTA Allian Also on Tuesday, RISI hosts a sem- Ambassador Room, 2nd Level speakers, those who do not have hurting vulnerable citizens by tak- From Donna Harman, the future of the paper industry. in- • 8:00 a.m. – 12:00 p.m. -English ing away access to the paper option At the end of 2011, the savings bond and Kevin Gammo During a Monday morningry ses par- - inar on the market outlook for print- • 4:00 – 5:30 p.m. Extended Producer Responsibility – A Solution Seeking a Problem ready computer access, and tho is Official Hospitality Suites Open they need.” program went all-digital, replacing ing-writing paper, paperboard, and Industry Leadership S concerned about identity sion, Paper Check-off Panel mem- ession AF&PA – States are looking for new paper savings bonds with an online Schedule of Events recovered fiber. Topics will include (suites closed) • 12:00 – 2:30 p.m. No more paper Social Security bers answer questions indust packaging for their products woul electronic security. These actionsse legislative ways to divert waste from d Paper2013 Luncheon theft and process that requires an onli (all meetings and events are being held influences from technology, Asian Sponsored by Domtar pay the costs of collectin are being taken with little or no U.S. checks at the Fairmont Chicago) ticipants have about the proposed landfills, for both environmental g that same count for both the recipient and the supply growth, operating rates and International Ballroom, 2nd Level Sponsored by Graphic Packaging Congressional oversight and with- In the latest move by the U.S. Trea- Paper Check-off program and the - packaging for either recy giver. To activate an online Treane ac- - rising mill cash costs. and economic reasons. A growing cling or dis- and International Paper sury Department, on March Sunday, March 17, 2013 recently issued call for Board nomi- • 5:30 – 6:30 p.m. posal. out ample opportunity for pub Throughout Paper2013, other trend to address municipal solid International Ballroom, 2nd Level sury account, users must divulge • 12:00 – 6:00 p.m. Paper2013 Reception input. lions of Americans were forced to Kevin Gammonley nations. EPR can take one of four forms • personal information suc Paper2013 Registration sessions, suite meetings and various (open to all Paper2013 reg waste and recycling is called extend- at 2:30 – 6:00 p.m. switch from traditional social 1, mil- rest Tuesday’s Luncheon features re istrants) the state level: 1) produc “This lic Paper2013 Convention vel International Ballroom, 2nd Level ed producer responsibility (EPR). t-specific Official Hospitality Suites Open issue does not attract th Social Security number — opening Donna Harman association committee meetings rity checks to electronic direct d Daily Desks spected author, economist, educa- legislation; 2) framework legisla same kind of attention as th them up to the rising ris h as their P’13 Lounge will take place. tion; posit or a Treasury-issued debit cardsecu- tor and speaker Dr. Jeffrey Rosens- EPR is a policy that 3) solid waste management cliff or air regulations, but govern-e fraud. Anecdotal reports i Moulin Rouge Room, Lobbyites LeOpen On behalf of the American Fo We hope that you find the pro-TUESdAy, MARch 19, 2013 plan; or e fiscal to receive federal benefits for Soci weig. Known for his unique ability to 4) executive order. In 2 ment mandates that decrease the e- that many long time bondk of buy cyber- 4:00 – 6:00 p.m. & Paper Association (AF&PA) and gramming and networking opportu- would shift total financial 013, Iowa, Security, SSI disability, ve • deliver original and useful business • 8:00 a.m. – 4:00 p.m. Maryland, Massachusett demand for paper are a th Official Hospitality Su the NPTA Alliance, welcome to responsibility for the s, New Mex- will no longer use this importndicate nities valuable and interesting. We Paper2013 Registration other federal programs. In addition,al content in an engaging and dynam- - ico, New York, and Rhode Island in- our industry needs to pay atten- terans’ and savings tool. Paper2013 in Chicago! appreciate your participation andPaper2013 Convention “end-of-life” recovery of reat that the Social Security Administration ers MOnday, March 18, 2013 your ic presentation style, Dr. Rosens- troduced solid waste management/ tion to, particularly since they set This year’s “Passport to Opportu- wish you the very best for 2013. Daily Desks packaging and printed paper has already eliminated the mai No more tax forms in the mailboxant • 7:00 a.m. – 5:30 p.m. weig will focus his presentation on recycling and EPR legislation. the stage for adoption in t nities” includes a variety of sessions P’13 Lounge The IRS no longer distributes an Paper2013 Registration emerging markets as well as eco from the municipality to the of annual earnings statements, an Paper2013 Convention and chances to network with Moulin Rouge Room, Lobby Level The paper and paper-based pack- he pri- important financial planni ling nual tax forms. While the IRS want Daily Desks bby Level nomic, business and demographic manufacturer or brand owner. aging industry recogniz industry colleagues. • 8:00 a.m. – 12:00 p.m. es the im- AF&PA Congressional Priorities taxpayers to file electronically, mil- P’13 Lounge trends impacting the paper and used by millions of Americans. - Monday’s Industry Leadership management efficiency, andOfficial re- Hospitality Suites Open portance of recycling and div ng tool Moulin Rouge Room, Louites Open onal aging EPR is a policy that wou erting As the first quarter of 2013 unfo lions of citizens still file their re s Session kicks off our program with ® duced environmental impacts — ld shift materials from landfills, 8:00 a.m. – 4:00 p.m. Initiative — Paper-based Packaging• 12:00 – 2:30 p.m. total financial responsibility for the which is Congress is embroiled in fiscal pol- • all of which contribute to respon- why it has spent consid 2011. The industry’s recove Official Hospitality S mation a distinguished panel of CEOs rep- Paper2013 Luncheon “end-of-life” recovery of packaging erable re- ry rate icy debates. While Congress passedlds, turn sible and affordable pack sources to build a market-based in- far outpaces all other commoditie (continued on page 4) • 10:30 – 11:00 a.m. resenting key segments of the paper youth and family-based educati Sponsored by Graphic Packaging and printed paper from the mu- s tax legislation in early January, other Postal Reform solutions. in the municipal solid wast Paper Check-off Infor marketing firm Kaleidoscope to de- and International Paper nicipality to the manufacturer or frastructure to recover and recycle e stream. fiscal issues were left for the Approximately one-third of printi Session grade students. Officially launched in 2009, The Re- The goal of EPR — to - 6th International- Ballroom, 2nd Level its own products. The industry con- increase re- and writing paper demand “Investing in our Future – The responsible Packagestain- velop a youth education outreach brand owner. This means gress to address this spri sponsible Package is funded by the that the tinues to inform and remind legisla- covery rates and reduce the amount Biobased Labeling and Federal The Paper Check-off” 2nd Level program for 3rd • 2:30 – 6:00 p.m. companies who produce and/ AF&PA is working to educateCon - ered through the mail system. Withng The Responsible Package initiative following organizations: American or of recyclable products going to ng. is deliv- Procurement (open to all Paper2013 registrants) The program educates kids and their Official Hospitality Suit tures of its recycling commitment members of Congress ab financial losses exceeding $ Ambassador Room, promotes the versatile and su es Open use the printed product . landfills — is commendable. How- ession Forest & Paper Association, Asso (magazines, More than 60 percent of paper c lion in 2012, the U.S. Postal Service USDA’s Biobased Markets Program families on the benefits of paper- newspapers, catalogs, pac on- dustry’s economic impact and • 4:00 – 5:30 p.m. able packaging solutions provided ciation of Independent Corrugated kaging of ever, serious concerns exist regard- out the in- 15 bil- comprises two separate initiatives: based packaging and helps them consumer and durable g sumed in the U.S. has been r commitment to sustainabil (USPS) must change signific Industry Leadership S by paper-based packaging such as Converters, Corrugated Packaging oods etc.) ecov- ing the practical implementati Product Labeling, which al (suites closed) 2nd Level to understand why paper-based ered for recycling in each of on of issue the industry faces has an effect our to return to profitability and estab- paperboard, corrugated, and paper Alliance, Fibre Box Association, Pa- and/or the companies who use that the last any specific product stewards USDA to authorize manufacturers Sponsored by Domtar packaging is a responsible option or three years, exceeding 6 hip on its 900,000 workers — whity. Every lish a sustainable business moantly International Ballroom, bag and sack products. perboard Packaging Alliance, Pa- 6 percent in and vendors of biobased prolows the rants) choice. (continued on page 6) dealing with marketplace challeng- Their attempt at a solution was a 5:30 – 6:30 p.m. To discover new ways to promote perboard Packaging Council, Paper to use a “USDA Certified Biobase • Level es, a struggling economy, or s ether hasty announcement to elimi del. Paper2013 Reception the recyclability and sustainability The research identified action- Shipping Sack Manufacturers’ Asso-re Product” designation on pr ducts (open to all Paper2013 regist government regulations. Through six-day mail delivery eff of paper-based packaging to young- able insights for the paper-based ciation, and Renewable Bag Council. t WANT A SUPPLIER THAT’S THERE FOR YOU the marketplace, and a Federal Pro- International Ballroom, 2nd find learn more about our working with our member tifling gust of this year. This decision winate d er generations, The Responsible packaging industry to ensure the To ective Au- curement Preference, whichoducts in nies and industry allies, AF&PA has put mailing industry jobs at ris uESday, March 19, 2013 Package launched two projects. TRU most recent projects and learn mo TODAY T presence and use of its products AND TOMORROW? AF&PA will continue to support leg preference for the purchase of bio Research, a global leader in youth identified several prioritycompa issues- ll • 8:00 a.m. – 4:00 p.m. in future generations. about paper-based packaging, visi Since the days of President Lincoln, Glatfelter based products by the federagives a Paper2013 Registration has served the paper industry with an including postal reform; islative measures that will help k. research and insights, conductedch www.theresponsiblepackage.com. unwavering commitment to ernment. Despite the clear language Paper2013 Convention vel quality, service and sustainability. Today we are labeling and federal procurement; USPS achieve financial stability by - the first project, which explored Mil- Be sure to follow us on Twitter too @ strong global supplier, capable a financially - of the 2008 legislation defin l gov- Daily Desks The paper-based packaging in- of meeting your most challenging demands. paperless government; tax; aibiobased encouraging new revenue s the P’13 Lounge lennials’ (ages 16-27) views of pa- PaperbasedPkg.Learn why Glatfelter has been in business for 14 “biobased” product as “a product dustry has an impressive story to 9 years — Suite 523 at the Fairmont Chicago, Millenni lations; and energy. attracting customers, and realizing Moulin Rouge Room, Lobby Le per-based packaging. The resear um Park | www.glatfelter.com composed in whole or sig ing a tell, one that includes sustainable gla001901-01PaprWk13Bnr-D11d.indd 2 r regu- cost savings without sacrificingources, cus • 8:00 a.m. – 12:00 p.m. identified actionable insights for the part of biological pro Official Hospitality Suites Open forestry, exceptional recovery rates tomer-facing opportunities to gen- aging paper-based packaging industry to ing renewable domestic agriculturenificant 12:00 – 2:30 p.m. for recycling, energy and waste 2/28/13 10:19 AM erate new business. ducts, includ- • ensure the presence and use of its 900365_Pap2013_MON_36.indd 1 - Paper2013 Luncheon vel ORd OF SEARCHING FOR A SUPPLIER THAT and forestry materials,” USDA ar- Sponsored by Graphic Pack products in future generations. ec bitrarily excludes the majority of For the second project, The Re- cK R and International Paper n tRA N 3/7/13 2:03 PM International Ballroom, 2nd Le sponsible Package partnered with ve NEVER STOPS IMPROVING? RO (continued on page 5) • 2:30 – 6:00 p.m. Official Hospitality Suites Ope Find out how Glatfelter is investing in your success At Glatfelter we are committed to continually improving every aspect of our business, investing 2/28/13 10:19 AM in capabilities, products and PEOPLE so that we can keep your business moving forward. LOOKING FOR A p gla001901-01PaprWk13B nr-D11d.indd 3 — Suite 523 at the Fairmont Chicago, Millennium Park | www.glatfelter.com 3/7/13 11:21 AM INNOVATION AND EXPERTISE? 900366_Pap20 13_TUE_20.indd With highly specialized capabilities, world-class R&D and a powerful| www.glatfelter.com new product 1 development engine, Glatfelter consistently drives more than 50% of it’s business from products developed in the last five years. the Fairmont Chicago, Millennium Park

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900364_Pap2013_SUN_24.indd 1 Reach Decision Makers Place an ad in the Paper2014 Convention Daily

Due to comprehensive networking of Paper2014 Published during Paper2014 in New York, the attendees, the Paper2014 Convention Daily offers Paper2014 Convention Daily delivers news and a unique advertising opportunity for: industry information such as:

• Pulp producers • A complete, up-to-date schedule • Paper manufacturers of meetings and activities • Tissue manufacturers • Program reviews • Paperboard producers • Session reports • Paper converters • Speaker interviews • Paper merchants • Industry news and statistics • Suppliers of equipment and service • Hospitality suite locations and contact information Paper2014 is scheduled for March 23-25, 2014 in New York. For further information on advertising opportunities in the Paper2014 Convention Daily, please contact: Mike O’Brien, Publisher • O’Brien Publications, Inc./PaperAge • 20 Schofield Road • Cohasset, MA 02025-1922 Telephone: 781.923.1016 • Fax: 781.923.1389 • e-mail: [email protected]

The Paper2014 Convention Daily will be published in three separate editions (March 23rd, March 24th, and March 25th) and distributed to all attendees of the Paper2014 meeting in New York. The Paper2014 Convention Daily is published by O’Brien Publications, Inc. water treatment Microbiological Auditing and Control – A New and Powerful Approach to Controlling Problem Organisms

A genetic-based technique used to detect and identify troublesome microbes in paper mills’ fresh water systems has been found to be quick, accurate, and less cumbersome than traditional methods.

By David Oppong and Tod Stoner

Editor’s Note: This article was first presented at PaperCon 2013.

resh water contamination of paper mill systems may it can be retrieved to help identify and treat problems found lead to outbreaks of deposits of filamentous bacteria in other mills. often collectively called “pink slime.” These deposits can F INTRODUCTION be difficult to treat with modern microbiological control The problems caused by uncontrolled growth of microor- programs, especially in mills where corrosion is a concern. ganisms in the production of paper are well known. These We have adopted a methodology that uses DNA fingerprint- include odor, paper stains, web breaks, slime, blockage of ing to identify problematic fresh water organisms. Once the pipes, and corrosion.1 Microorganisms enter the produc- microorganism is isolated and identified, we can then use tion system from a variety of sources such as raw materials, our available biocidal actives to identify the most appro- water, soil, and air. The control of microorganism is usually priate formulations so that the deposit can be effectively accomplished with the use of biocides and/or dispersants as treated. Even though problem organisms can manifest in well as good housekeeping including boil out of the system similar ways, specific problem organisms can vary widely in where appropriate. the optimum product and MIC required to control them. In preparation for effective microbial control of a system, Thus, by utilizing the state of the art technology to iden- a good audit of the system helps as this can give a picture of tify problem organisms, we not only provide our customers the types, nature, and the relative abundance of the microor- with some of the most advanced control chemicals, but the ganisms that may be causing the problem. The use of the resulting information is also entered into a database where

22 JANUARY/FEBRUARY 2014 PaperAge water treatment microscope, visual inspection, ATP assays, and also microbial tures using the instructions provided in the PrepMan Ultra plate counts are some of the techniques frequently Sample Preparation Reagent Protocol (Applied Biosystems). employed in the auditing process. GENE AMPLIFICATION DNA methods for detecting and Once DNA is obtained, a polymerase chain reaction (PCR) is run. PCR is a method for amplifying or making identifying microorganisms have millions of copies of a particular gene sequence.8 In iden- become increasing popular. tifying eubacteria, the 16S rRNA gene is amplified. This gene is used in the identification of most bacteria because 9 DNA methods for detecting and identifying microorgan- it is expected to occur in all bacteria. The 16S rRNA gene isms have become increasing popular. They have been used is also conserved which means it has changed very little in the leather industry,2 pulp and paper 3, 4, 5, 6, 7 and have over the evolutionary period. Additionally, the 16S rRNA played significant roles in expanding our knowledge of the gene has regions of significant sequence variability that microbial flora of these environments. It would be advanta- allows bacteria of different species to be differentiated or 10 geous if some of these techniques could be incorporated identified. into microbiological auditing programs and routinely used A PCR reaction mixture would include the template to detect and identify troublesome microbes in paper mills. DNA, primer set to initiate the reaction, thermostable DNA In this presentation, we describe a genetic-based identifi- polymerase, nucleotides (dNTP’s), magnesium, and a buffer. cation technique that we have found to be useful and which All reagents and method for amplifying the 16S rRNA gene we frequently employ together with the other established are contained in the MicroSeq 500 16S rDNA Bacterial auditing tools when we initiate microorganism control in Identification PCR Kit (Applied Biosystems). a system. We also present the use of these techniques in At the end of the reaction, the success of the PCR is studying the “pink slime bacteria” in deposits from six checked by taking a sample of the reaction mixture and run- different mills. ning agarose gel electrophoresis. If the expected band can be visualized on the gel, the PCR is deemed to be successful SAMPLING AND ISOLATION OF BACTERIA and the product is cleaned up of the unreacted reactants. The first step in using DNA based auditing method involves selection of sampling points. Typically, we obtain samples 16S rRNA SEQUENCING AND DATA ANALYSIS from several points of interest including water and slime The cleaned amplified DNA is used in cycle sequencing. deposits. Samples of slime deposits and incoming water DNA sequencing is a method that allows us to determine are collected and sent to the laboratory for microbiological the order or sequence in which the bases (A, T, G, C) occur analyses. The samples are processed immediately after arrival in a particular gene or DNA. Cycle sequencing utilizes four at the laboratory. Samples are aseptically processed by serial different fluorescent dyes to covalently label the correspond- dilution in sterile saline and plated on plate count agar, R2A ing bases in the DNA. 11 agar, Stokes agar, and actinomycetes isolation agar. The plates 16S rRNA gene sequences of the isolates are generated are incubated at 30⁰C or 45⁰C-50⁰C (depending upon field using the MicroSeq 500 16S rDNA Bacterial Identification conditions) for 2-7 days and colonies picked, and re-streaked Sequencing Kit (Applied Biosystems). After cycle sequenc- to obtain pure cultures of bacteria. The isolation could also ing, the reaction mixture is cleaned up to remove unreacted be done by streaking the original samples onto appropriate reactants and unincorporated dyes according to the method plates, but we usually use the serial dilution method as this provided by the manufacturer. also affords us the chance to estimate the relative numbers The reaction products from the cycle sequencing are then of bacteria that may be causing the problem. electrophoresed on an automatic DNA sequencing machine. DNA PREPARATION Sequence analysis and bacterial identification are per- The genetic method for the identification is based on the formed using Applied Biosystems’ MicroSeq microbial MicroSeq system from Applied Biosystems, Foster City, analysis and database. In a case where there is no match, a California. The method requires the use of DNA from pure BLAST search of the GenBank or Ribosomal Data Project is cultures of bacteria. The DNA is extracted from the cul- conducted for a possible match.

PaperAge JANUARY/FEBRUARY 2014 23 water treatment

RESULTS AND DISCUSSION to be Runella sp. These are filamentous bacteria and they 13 A genetic-based identification system was used to study the have been isolated in a wastewater treatment plant and 14 composition of “pink slime bacteria” in pink slime deposits water bodies, but neither information about their occur- prior to instituting slime control programs. The samples rence in paper mills nor their association with “pink slime” came from mills located in the US, China, Germany and the in paper mills has, to date, been published. Czech Republic. Detailed identification of the culturable Meiothermus ruber and Deinococcus geothermalis were bacteria was done for samples obtained from three of the identified as the cause of the pink slime in one of the mills mills. For the remaining samples, attempts were made to studied. In this mill, Meiothermus ruber was found to be the isolate only pink-or-red-pigmented bacteria. Table 1 shows dominant pink or red-pigmented bacteria. These organisms the bacteria identified in the deposits from the various mills. are moderately thermophilic and they were isolated at 45 In the six mills studied, the main cause of pink slime - 50˚C. The presence of Meiothermus sp. and Deionococcus varied to include Flectobacillus sp, Runella sp, Meiothermus geothermalis in slime deposits and as the cause of red or pink ruber, Deionococcus geothermalis, and Serratia marcescens. slime in paper machines has previously been reported.6 Flectobacillus sp. are pink-pigmented filamentous bacteria. In the 1950s, Serratia sp. were commonly associated with In this work we found them in three of the mills studied. pink slime in paper mills,15 but many studies in recent times This study, coupled with our experience from many other have shown many different bacteria other than Serratia sp. studies, 3, 4, indicate that they are the main cause of pink as the cause of this problem. 3, 4, 6 Interestingly, in one of the coloration in many “pink slimes” in modern paper machines. mills in the current study, Serratia marcescens was the domi- In one mill, Flectobacillus sp. were found together with nant pink- or red-pigmented bacteria found and the cause of Rhodovarius lipocyclicus which were red-pigmented but pink slime outbreak in that mill (Figures 1 and 2). Possible short rods. Rhodovarius sp. have been found in other reasons why Serratia sp. have become rare in recent times places12 but no information about their occurrence in the have been explored3 and these included changes in machine paper mill environment could be located. design and operation, paper making technology, furnish In one of the mills, the cause of the pink slime was found types, biocides, and other additives.

Table1. Composition of “pink slime bacteria” from deposits from 6 different mills Mill 1 Mill 2 Mill 3 Mill 4* Mill 5* Mill 6* (US) (US) (Germany) (Czech Republic) (China) (US) Flectobacillus sp. Runella sp Flectobacillus sp Meiothermus Serratia Flectobacillus major ruber marcescens Ralstonia sp. Sphingomonas sp Caulobacter sp Deionococcus Rhodovarius geothermalis lipocyclicus Janthinobacterium Bacillus cereus Aquaspirillum sp. Aquitalea sp. Acinetobacter Acinetobacter anitratus anitratus Asticcacaulis Cytophaga sp Pseudomonas extrincus resinovorans Burkholderia sp. Chromobacterium violaceum Herbaspirillum sp Klebsiella pneumoniae Sphingomonas sp. Staphylococcus epidermidis Uncultured/ Asticcacaulis Unidentified bacteria extrincus Uncultured/ Unidentified bacteria

*Study was designed to isolate only pink-or red pigmented bacteria.

24 JANUARY/FEBRUARY 2014 PaperAge water treatmentfeature

Figure 1. Serratia marcescens “red slime.” Figure 2. Serratia marcescens culture.

Furthermore, a number of bacteria were isolated and the paper mill slimes. J. Ind. Microbiol. Biotechnol. 25:78-80. 16S rRNA gene sequenced but could not be “named” as 4. Oppong, D., King, V.M., Bowen, J. 2003. Isolation and character- ization of filamentous bacteria from paper mill slimes. Internat. these bacteria either may not have been fully characterized, Biodeterior. & Biodegrad. 52:53-62. or may not have been cultured in the laboratory before. 5. Desjardins, E., Beaulieu, C. 2003. Identification of bacteria con- These were designated “uncultured/unidentified.” One inter- taminating pulp and a paper machine in a Canadian paper mill. J. Ind. Microbiol. Biotechnol. 30:141-145. esting and unique thing about the use of sequence-based 6. Kolari, M., Nuutinen, J., Rainey, FA., Salkinoja-Salonen, T., M.S. identification in auditing is that the sequences of these 2003 Colored moderately thermophilic bacteria in paper-machine “uncultured/unidentified” bacteria can be stored in a search- biofilms. J. Ind Microbiol. Biotehcnol. 30:225-238. able database and used in future searches. This database and 7. Suihko, M. L., Sinkko, H., Partanen, L., Mattila-Sandholm, T., Salkinoja-Salonen, M., Raaska, L. 2004. Description of heterotro- experience of how to control these bacteria provide a ready phic bacteria occurring in paper mills and paper boards. J. Appl. tool in the event of pink slime outbreaks. Microbiol. 97:1228-1235. In conclusion, the identification system described in this 8. Mullis, K.B., Faloona, F.A, 1987. Specific synthesis of DNA in vitro via a polymerase chain reaction. Methods Enzymol. 155:335-350. study was found to be quick, accurate, and less cumbersome 9. Woese, C. R. 1987. Bacterial Evolution. Microbiol. Rev. 51:221-271. than the traditional methods. It allowed a large number 10. Fox, G. E., Pechman, K. R., Woese, C. R. 1977. Comparative cata- of isolates to be identified in a relatively short period of loging of 16S Ribosomal Ribonucleic Acid: Molecular approach to time. The 16S rRNA gene sequences for the organisms are Procaryotic systematics. Int. J. Syst. Bacteriol. 27:44-57. stored in a database which can easily be searched when the 11. Tracy, T.E., Mulachy, L.S. 1991. A simple method for direct auto- mated sequencing of PCR fragments. Biotechniques 11:68-75 need arises. Additionally, the susceptibility of most of these 12. Kämpfer P, Busse HJ, Rosséllo-Mora R, Kjellin E, Falsen, E (2004). microbes to various control agents have been determined Rhodovarius lipocyclicus gen. nov. sp. nov., a new genus of the alpha- (no data reported in the current work) and this informa- 1 subclass of the Proteobacteria. Syst. Appl. Microbiol. 27:511-516. tion, among others, is used in making timely decisions about 13. Lu, S., Lee, J. R., Ryu, S. H., Chung, B. S., Choe, W-S., Jeon, C. O. 2007. Runella defluvii sp. nov., isolated from a domestic wastewater n appropriate control strategies for a particular situation. treatment plant. Int J. Syst. Evol. Microbiol. 57:2600-2603. 14. Larkin, J. M., Williams, P. M. 1978. Runella slithyformis gen. nov., sp. LITERATURE CITED nov., a curved non-flexible bacterium. . Int J. Syst. Evol. Microbiol. 1 . Ross, R.T., Hollis, C.G. 1976. Microbiological deterioration of pulp- 28:32-36. wood, paper and paint. In: Miller, B.M., Litsky, W. (Eds.), Industrial 15. Sanborn, J.R. 1951. Relation of red slimes to the general paper mill Microbiology. McGraw-Hill, New York, NY, pp. 309-354. slime control. TAPPI 34:490-493 2. Oppong, D., Bryant, S.D., Rangarajan, R., Steele, S. 2006. Application of molecular techniques to identify bacteria isolated David Oppong is Senior Biotechnology Research Scientist, and from the leather industry. ALCA 101:140-145 Tod Stoner is Product Specialist - Deposit Control at Buckman. 3. Oppong, D., King, V.M., Zhou, X., Bowen J. 2000. Cultural and For further information, please contact David Oppong: d_oppong@ biochemical diversity of pink-pigmented bacteria isolated from buckman.com.

PaperAge JANUARY/FEBRUARY 2014 25 featurereliability maintenance - lubrication Keep it Running Smooth

To succeed in today’s fiercely competitive marketplace, pulp and paper manufacturers positively, absolutely, require maximum equipment availability and productivity from their machinery, and a disciplined lubrication management program can make this happen.

By Tom Schiff

hether your mill is producing pulp, printing and writ- THE IMPORTANCE OF A LUBRICATION ing grades of paper or containerboard, maintaining a MANAGEMENT PROGRAM Wsafe work place, complying with applicable laws and Most people believe just maintaining or adding lubricant producing profitable products with maximum quality are to the rotating equipment provides effective lubrication. all sound objectives for a world-class company. But, what However, by not implementing lubrication program man- does it take to accomplish these objectives? To be success- agement, the opportunity to optimize equipment reliability ful, manufacturers like yourself positively, absolutely, require and maximize the return on your investment may be lost. maximum equipment availability and productivity of your Disciplined lubrication management is the foundation of a paper machines and auxiliary equipment. To make that hap- world-class lubrication program. The following chart illus- pen you need a disciplined, world-class lubrication program. trates the difference made in a plant’s total cost of owner- This can be achieved by establishing some guiding principles ship once you’ve taken that step. that include: Remember that implementing a disciplined lubrication 1. Setting the importance of a lubrication management management program comprises only one part of an overall program. equipment reliability improvement program. Sound preven- 2. Defining the lubrication management program goals, and... tive/predictive maintenance activities combined with good 3. Implementing the tools required to achieve the lubrica- maintenance planning, scheduling, and execution are also tion management program goals. key to delivering maintenance improvements.

26 JANUARY/FEBRUARY 2014 PaperAge reliability maintenance - lubricationfeature

LUBRICATION MANAGEMENT Leadership. First and foremost, PROGRAM GOALS lubrication needs to be a priority for To properly define the goals of your maintenance managers. Many com- lubrication management program, panies look at lubrication on a price use the following list. Choose those basis and strive for methods to mini- goals that will best meet your com- mize that cost. Unfortunately, when pany’s needs: this happens, you may run the risk of • Reduce lubricant related failures forfeiting the true payback that can result from optimizing your lubrica- • Use the fewest correct lubricants tion program — improved equipment and minimize waste reliability AND decreased overall • Apply the lubricant in the correct maintenance costs. Be sure to nomi- manner, at the proper time and in nate a program champion — someone the correct amounts who will assume the responsibility, • Integrate the plant’s preventive Most people mistakenly believe accountability and control for the and predictive maintenance goals just maintaining or adding lubricant program. Plan for continual improve- into the lubrication program to the rotating equipment ment and measure your progress on a provides effective lubrication. • Continually investigate and imple- regular basis. ment methods to improve and A good program requires dedica- achieve the above goals tion, skill and accountability. The discipline to “stick with it” Once you’ve defined the goals of your lubrication man- comes from strong leadership. agement program, next you need to be sure you have the Standard Operating Procedures (SOPs). Like other dis- proper tools that will enable you to achieve these goals. ciplines (operating or repairing machinery), SOPs can help BASIC TOOLS REQUIRED FOR AN EFFECTIVE guarantee repeatability and quality work. Also, SOPs assist in PROGRAM the training of lubricators and enable you to track and com- No single program works for everyone. There are many dif- municate equipment condition. ferent methods to achieve the goals of your lubrication man- Teamwork and Communication. A world-class lubrica- agement program. No matter what method you implement, tion program must have a team that works and communi- to ensure success, you should use the following tools. cates with all members of the manufacturing group opera-

Description Before After Annual Lubrication Costs including Labor, Lubricant Costs and Supply Costs $1,055,000 $845,000 Total Annual Maintenance Budget $24,000,000 $22,000,000 Percent Annual Lubrication Costs vs. Total Maintenance Budget 4.4% 3.80% Lost Annual Availability Due to Scheduled and Unscheduled Maintenance 6% 2% Estimated Annual Profit Lost Due to Lost Equipment Reliability $3,500,000 $1,200,000 Annual Maintenance Department Overtime 22% 14% Annual Number of Equipment Failures Due to Poor Lubrication 18 2 Annual Volume of Lubricant Consumed (gallons) 62,000 15,000

Note: Table shows example numbers for demonstration purpose only.

PaperAge JANUARY/FEBRUARY 2014 27 reliability maintenance - lubrication

tions, maintenance, science of lubrication purchasing, planning audits can become very and engineering. The involved, however, and team champion is key deserves a paper of its is maintaining the com- own. munication and keep- CONCLUSION ing the team focused. Lubrication Safety, compliance, Scheduling, Planning, and maximum qual- and Tracking Manage- ity manufacturing are ment Systems. sound objectives for a To handle the quantity world-class company. A of data encountered disciplined lubrication (even for a small plant), management program an effective computer- is what’s needed to achieve these objec- ized system should be To continually improve, both program leader and lubricators employed. Without must continually learn best lubrication practices, as well tives. And, when you the aid of computer- as learn new techniques in their specific discipline. set goals that put in ized data management, place the tools you important equipment trends may be missed and/or docu- need to succeed, you are well on your way to establishing a n mentation of the lubrication program may be lacking. world-class lubrication program. Training. To continually improve, both program leader Tom Schiff is Americas Field Engineering Manager for Exxon Mobil Corporation. He has nearly 20 years of experience with ExxonMobil and lubricators must continually learn best lubrication and for 8 years has held the positions of Reliability Engineer and practices, as well as learn new techniques in their specific Maintenance Superintendent for a prominent paper producer. For discipline. further information about lubrication management, please visit: www. mobilindustrial.com/ind/english/contactus.aspx. Metrics. Knowing the past performance and understand- ing the effects of program efforts enable you to make and evaluate lubrication program -related decisions. The follow- ing metrics are useful when tracking your program’s progress (other metrics not listed below may also prove useful). • Total maintenance costs and percent spent on lubrication • Percent of equipment scheduled and unscheduled downtime • Number of lubricant related failures • Percent of maintenance overtime labor • Lubricant consumption • Safety Incidents Audits. In order to improve, you need to validate or audit your lubrication program. Whether performed inter- nally or by a third party, the effort to benchmark and evaluate your lubrication program against other “best in class” operations will supply tremendous dividends. The

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PaperAge JANUARY/FEBRUARY 2014 29 recycling matters Continuous Commitment to Paper Recovery for Recycling Paper recovery has fostered a dynamic marketplace that allows recovered fiber to find its highest-value use, which helps to encourage even more recycling.

By Donna Harman, President and CEO, American Forest & Paper Association

Recovering paper and paper-based tive and cost-effective programs and products for recycling has long been a partnerships. The program generates priority for our industry and an effort interest in developing new recycling in which AF&PA members continue programs; provides a resource to those to be proven leaders. Since 1990, looking to start or improve paper when we first set a nationwide paper recovery programs; and supports the recovery goal, the U.S. recovery rate industry’s on-going effort to increase has nearly doubled, topping 65 per- recovery and maintain the quality of cent in 2012. According to the U.S. recyclable paper. Environmental Protection Agency, in Now in its ninth year, the AF&PA 2011, only 27.6 percent of glass, 20.7 Recycling awards program has been percent of aluminum and 8.3 percent The paper recycling industry collects, sorts redesigned and continues to provide and processes recovered paper into new of plastics were recovered from great visibility and reward those paper and paper-based packaging products municipal solid waste streams. that were valued at $8.4 billion in 2012. engaged in successful paper recycling Recovering paper products extends efforts. the fiber supply, which allows our industry to reuse its products In each category — school, business and community —there to make new ones. It also saves an average of 3.3 cubic yards of are now four chances to win. Programs will no longer be judged landfill space for each ton of paper recycled. for their all-over performance, but on specific characteristics, AF&PA member companies have taken efforts to develop namely: volume – the total amount of paper and paperboard and nurture a voluntary, market-driven system that fosters collected; creativity – unique and innovative ways that have consistently high rates of paper recovery. Our sustainability been used to market the program, raise awareness and generate initiative — Better Practices, Better Planet 2020 — includes a interest; participation – unique and innovative ways success- goal to exceed 70 percent recovery of all paper used in the U.S. ful programs increased participation and tonnage collected; by the year 2020. Our members continually take strides and partnerships – innovative partnerships with communities, to improve the recovery of paper and paper-based packaging. businesses and/or non-profit organizations used to promote The paper recycling industry collects, sorts and processes increased recovery. recovered paper into new paper and paper-based packaging This structure will allow for a greater focus on elements products that were valued at $8.4 billion in 2012. And the that drive improved paper recovery program performance and value of U.S. recovered paper exports totaled $3.5 billion in increase recovery overall. It will also allow us to expand our 2012. All in all, paper recovery has fostered a dynamic market- reach and provide opportunities for more parties to engage and place that allows recovered fiber to find its highest-value use, enter the program. which helps to encourage even more recycling. Descriptions of the awards, entry criteria and entry forms are But paper recovery for recycling is a collective effort. all available on paperrecycles.org. The deadline for all entries is Ultimately, it is possible and successful thanks to the commit- March 7, 2014. ment of millions of Americans who make the effort to recycle Our industry has a proud tradition of achievement in paper at home, work and school every day. recovery for recycling, and we are looking forward to recog- We recognize excellence in paper recovery for recycling nizing the invaluable involvement of businesses, schools and through our annual AF&PA Recycling Awards program. communities in making paper recycling a success. Paper offers First launched in 2006, the AF&PA Recycling Awards a recyclable product made from a renewable resource, which recognize and highlight businesses, schools and communities is one of many strong points that makes paper the choice that that increase paper recovery through educational, innova- consumers can trust and be proud to use. n

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Paper2014 Luncheon keynote speaker: Alex Sheen Founder of Because I Said I Would Early bird registration closes February 28. Register today at Paper2014.com Committed to moving our customers’ performance forward – every day

Valmet Corporation is now an independent, listed company that was reborn through the demerger of the pulp, paper and power businesses from Metso Group in December 2013. We develop and supply competitive services and technologies for the pulp, paper and energy industries. Valmet’s services cover everything from maintenance outsourcing to mill and plant improvements and spare parts. Our strong technology offering includes entire pulp mills, tissue, board and paper production lines, as well as power plants for bio-energy production. Valmet and Metso will continue to work closely together to offer winning automation solutions. Our 11,000 professionals around the world work close to our customers and are committed to moving our customers’ performance forward – every day.

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