CUSTOMER’S VOICE Successful conversion from paper to board A marvelous journey rowth in traditional retail and e-commerce is increasing global demand for “PM 3 is almost like a new machine sustainably produced packaging materials. now; a combination of brand- In 2015, Stora Enso’s Varkaus mill in Finland converted their existing paper new technology and good, well- Gmachine into a board machine to produce linerboard to better meet the market need for renewable packaging. maintained trusted technology”, says They chose Valmet as their partner for this challenging rebuild. Jukka Lyyra, Area Manager of Paper “Every paper engineer has a dream about building a Machine & RCF Plant, Stora Enso. new machine” says Jukka Lyyra, Area Manager of Paper Machine & RCF Plant, about the conversion project, with TEXT Kaisamaija Marttila and Pauliina Purola a boyish grin. “I’ve been fortunate, as this is my second FORWARD 2/2016 17 StoraEnso Varkaus PM 3 Current grade: AvantKraft Brown (kraft liner) and AvantKraft White Top (white-top liner). Previous grades: first newsprint, and then fine paper Basis weights: 80–225 g/m² Wire Width: 8,400 mm Design Speed: 1,200 m/min Annual Capacity: 395,000 t/a Safety is project in this role. It has been a marvelous journey,” PM 3 had gone through a previous transformation from top priority at he continues. “PM 3 is almost like a new machine now; news to fine paper in 1985. Stora Enso and one of the most a combination of brand-new technology and good, In order to make the latest paper-to-packaging conver- important things well-maintained trusted technology. The opportunity to sion a reality, the machine was fortified with new refiners, to consider produce high-quality products with reasonable costs is a new headbox, a forming section rebuild including a when choosing t h e re .” Fourdrinier extension with a new top forming unit, a suppliers. Valmet met the strict press section rebuild with a new SymBelt press nip, as requirements. From paper to packaging well as rebuilds of the dryer section, calender, reel and The old fine paper machine was an excellent choice for a winder and the related air systems. To ensure consistent rebuild: the Varkaus mill has good facilities, reliable wood end product quality, a new Valmet Kappa Analyzer was and energy supplies, and skilled, motivated personnel. installed for the pulp mill and a Valmet IQ quality control Furthermore, the conversion was not the first of its kind: system (QCS) for the rebuilt board machine. Valmet’s re- “The opportunity to produce high-quality products with reasonable costs is there.” 18 FORWARD 2/2016 CUSTOMER’S VOICE Jukka Lyyra (on the left) and Ari Saarnio can now offer their customers sustainable, high-quality products of lower grammage. The OptiFormer multi- Fourdrinier forming section has two headboxes and the possibility to tune the pulps and furnishes for improved end product quality with cost savings. The improved fiber flow of an OptiFiner Pro refiner allows a smaller rotor, resulting in low no-load power, up to 50% lower than a traditional similar capacity refiner. tention measurement (RM3) analyzers provide real time For the Varkaus mill, cost competitiveness is a priority. information about wet end consistency and retention. “We try to use as few resources as possible. Raw material, Valmet also took care of the installation and testing, and energy and chemical consumption are all tied up with the provided start-up support and training along with fabrics machinery used and how optimized the processes are. Of for the machine start-up. course, we are serving our customers as well as possible in their quality needs, but in a way that means they can Right-weighting for resource savings choose our lower-grammage products – what’s known as “The whole wet end and multi-Fourdrinier forming sec- ‘right-weighting’ or ‘right-grading’”. tion is now very suitable for lightweight liner production: it has two headboxes and the possibility to tune the pulps Target: To be the number one for and furnish for improved end product quality with cost customers savings. It is proven, widely used technology, but there The Varkaus mill is determined to meet the needs of its are still new elements and technological advantages,” says customers who demand consistent performance in terms Lyyra about their reasons for updating the technology. of containerboard strength. Cleanliness is also important “The headboxes [one new OptiFlo and one relocated and because of the end uses involving food. Stora Enso is rebuilt with dilution control] seem already to be very suit- already receiving good feedback from the market. “For able for producing high-quality liner with stable profiles. us, the Valmet IQ QCS is very important, as it unites our And the brand new OptiFiner Pro refiners are saving us technology, quality control and processes. Reliable pro- energy and money,” he continues. FORWARD 2/2016 19 “Safety is our top priority at Stora Enso, and actually one of the most important things we consider when choosing suppliers.” cess measurements and making adjustments accordingly introducing additional lighting on older machine parts is one of the key points when producing high-quality for improved safety.” products. The technology permits modifying the pulp and raw material into the different plies”, Lyyra explains. Targeted start-up curve reached easily The mill is satisfied with the new quality control Starting up the machine after a rebuild may be one of the system. “The QCS is the heart of the production line. most rewarding and anxious moments in a papermaker’s It reliably monitors how well we succeed in producing job. Start-up represents the culmination of months of high-quality board and also fine-tunes the quality and hard work. A successful start-up means achieving the profiles according to customer expectations – and can desired paper quality and new product sales as planned, even exceed them,” Lyyra says. The Valmet RM3 analyz- and it also has a significant effect on how economical the ers ensure the stability of the wet end. Project Engineer project ends up being. Timo Vänttinen explains that the measurements have “The start-up went smoothly, considering that the made start-ups and grade changes faster. “It is vital to rebuild was large and we moved from paper to pack- have right process information to make right decisions at aging,” Timo Vänttinen explains. “We were able to get right time”, he explains. production going without many runnability issues, and we started the tune-up phase right away.” Lyyra adds Co-operation for good results that “the targeted start-up curve was reached easily – we “Of course, we considered all supplier options carefully. went even further than targeted. But then we faced some Valmet knew the mill well from previous projects, the challenges, which is normal. Now we are well on track technical solution was well suited to our needs, and Val- again. We still hope to achieve improvements in quality met’s location was close. It all matched well,” Ari Saarnio, and production, though.” Project Director, says. Stora Enso is also satisfied with the In this case, Valmet was also responsible for the instal- co-operation. “The teamwork during the project phase lation. “When a supplier is taking care of the installation, was very good, despite the tight schedules. Looking at the it makes our lives easier. And the supplier knows their big picture, the project has been a successful one.” machinery best,” Lyyra says. “Professionally, it has been a pleasure to work with Valmet. The Valmet team has been very open, reliable It’s the combination that takes and very easy to work with. There are always challenges performance forward when you’re dealing with a demanding project like this Valmet supplied the technology, the automation and the one. But that’s what project work is: finding solutions to fabrics for the start-up of the rebuilt machine. Having a the challenges quickly and efficiently. We have done that single point of responsibility is beneficial for all parties. work quite well with Valmet,” adds Jukka Lyyra, too. “With one supplier, there are fewer players and thus fewer overlaps in the start-ups. In my opinion, it lessens the Safety comes first ‘responsibility dodging’ and makes also the tune-up phase “Safety is our top priority at Stora Enso, and actually one and further development easier,” says Saarnio. of the most important things we consider when choosing Lyyra holds the same opinion. “It makes our lives eas- suppliers. Valmet met our strict requirements. We can ier. Having one supplier means they concentrate more on see that Valmet’s technology is safe, as it should be,” notes the whole production instead of a small part of it. Besides Saarnio. “The safety factors for installation and start-up making start-up smoother, this set-up makes sure that were carefully considered, but it went beyond that, as all everything is connected together well and works together the new equipment installed is safe to use and maintain.” in an optimized way, including Saarnio also mentions that there is always some in the tune-up phase. To- CONTACT PERSON overlap when combining old and new technology. “The gether with just one supplier, Sanna Röyskö standards of the new technology can set an example we can improve productivity Sales Director, EMEA [email protected] for the old technology, too. For example, we ended up and quality in a very efficient Tel. +358 10 672 9687 way.” 20 FORWARD 2/2016 CUSTOMER’S VOICE For the Varkaus mill, the new quality control system is the heart of the production line, monitoring reliably how well they succeed in producing high-quality board.