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Ian Melin-Jones

Ian Melin-Jones

Valmet introduces a full range of new, data-driven Industrial Internet solutions to pulp, board, paper, tissue and energy producers. The Valmet Industrial Internet (VII) solutions combine advanced monitoring and prediction applications, Advanced Process Controls (APC), dynamic process simulators and remote services from Valmet Performance Centers into comprehensive solutions that provide tangible benefits to customers.

VII solutions are tailored for each customer industry

The new VII solutions have been created for the specific needs of pulp, board, paper, tissue and energy producers. The purpose is to efficiently utilize data and Valmet’s expertise to reduce energy consumption, improve chemical and environmental efficiency, optimize pulp and paper quality, increase process reliability, maximize production and enable efficient management of the customer’s equipment fleet.

Performance Centers and Valmet Customer Portal are key elements of the VII solutions

Remote services from Valmet’s eight Performance Centers are a key part of the VII solutions. The Performance Centers make Valmet’s expertise easily available for customers through remote connections and tools.  

valmet logo rgbCustomers can collaborate with Performance Center experts, access the Industrial Internet applications, follow-up their Key Performance Indicators and see performance reports via Valmet Customer Portal.

“Our customers’ needs have been the starting point of developing these data driven Industrial Internet solutions. We have integrated our process, automation and services know-how and extensive Industrial Internet application portfolio into a value-added solution offering. Ultimately, the aim is to empower our customers to move toward autonomous plants or mills, which will result in significantly more efficient production processes and operations. We want to engage our customers in a dialogue with data to move their performance forward,” says Jari Almi, Vice President, Industrial Internet, Automation business line, Valmet.

Valmet will supply a Defibrator™ system to Çamsan Entegre Ağaç Sanayi ve Ticaret A.Ş in Turkey. The start-up of the system is planned for the middle of 2020.

valmet logo rgbThe order is included in Valmet’s orders received of the fourth quarter 2019. The value of the order will not be disclosed. An order with this scope of supply is usually valued in the range of EUR 2-5 million.

"The EVO 64 system is specially designed for production levels up to 35 tons per hour, which will be perfect for Çamsan Entegre in this case. We are really pleased that Valmet was chosen as the supplier in this project," says Leif Sundberg, Sales Manager, Pulp and Energy, Valmet.

Information about Valmet’s delivery
The scope of Valmet’s supply includes a complete EVO 64 defibrator system with a steam separator. This is the first steam separator delivery for Valmet in Turkey.

Information about the customer Çamsan Entegre Ağaç Sanayi ve Ticaret A.Ş
Çamsan Entegre is a Turkish Medium Density Fiberboard (MDF) and laminated parquet flooring producer. Their paper impregnation capacity is 90.000.000 m² per year. Çamsan Entegre is a domestic leader and is mainly exporting to Iran, Egypt, Iraq, T.R.N.C., Azerbaijan, Kuwait, Greece, Albania, Tunisia, Bulgaria, Kosova, Georgia, Turkmenistan and Afghanistan.

Valmet will deliver key process islands for Lenzing’s and Duratex’s joint venture named LD Celulose S.A. The new 500,000 ton/year dissolving pulp mill is located in the cities of Indianópolis and Araguari in Minas Gerais state, Brazil. Valmet’s delivery includes a fiber line, a pulp drying and baling line, an evaporation plant, a white liquor plant and a mill-wide automation system.

The order is included in Valmet's orders received of the first quarter 2020. The value of the order is not disclosed. The value of a delivery of this size and scope is typically around EUR 200-250 million.

Valmet’s delivery is part of the Lenzing and Duratex joint venture investment of approximately USD 1.3 bn in the 500,000 tonnes dissolving wood pulp mill where Lenzing holds a 51 percent and Duratex a 49 percent stake. The start-up of the new mill is planned for the first half of 2022 and will create approximately 8,000 direct jobs during the construction phase. When it is ready, LD Celulose S.A. will employ approximately 1,100 people to operate the industrial plant and the plantations that will supply it. The dissolving pulp is a key raw material for manufacturing Lenzing’s wood-based textile and speciality fibers.

“Wood-based cellulosic fibers offer an important contribution to enhance sustainability in the textile industry and this investment is in line with our growth strategy and a key milestone to structurally strengthen our cost leadership position. In planning the new production facility, particular importance was given to sustainability aspects. The plant will be among the most productive and energy-efficient mills in the world,” states Stefan Doboczky, CEO of the Lenzing Group.

“LD Celulose S.A. will bring a positive socioeconomic impact throughout the region. We are working with the best environmental practices and with leading companies in the pulp industry, such as Valmet,” emphasizes Luís Künzel, CEO of LD Celulose S.A.

“With our good references in dissolving pulp production technology and strong presence in Brazil we were able to meet the customer’s needs of high quality and energy efficiency as well as supporting high productivity and reliability with our automation solutions. We are happy to be a key partner in delivering a world class mill for Lenzing and Duratex and thus being part of turning renewable raw materials for sustainable textile fibers,” says Bertel Karlstedt, President, Pulp and Energy Business Line, Valmet.

The new 500,000 tonnes dissolving wood pulp mill is being built in Minas Gerais state, Brazil.The new 500,000 tonnes dissolving wood pulp mill is being built in Minas Gerais state, Brazil.

Information about Valmet’s delivery

Valmet will supply key process islands with an extended scope of supply. Valmet’s technology is proven for dissolving pulp production with several references. The equipment for this project is tailored for high availability and energy efficiency resulting in low operating costs.

The fiber line features Valmet TwinRoll technology for high washing efficiency with low chemical and water consumption. The pulp drying and baling line secures flexibility and high-quality pulp with easy operation supported by Valmet Quality Control System. The evaporation plant features Valmet Tubel technology for high availability and produces clean condensate quality for 100% reuse in the mill. The white liquor plant includes recausticizing and lime kiln and is designed for high reliability and less maintenance.

The mill-wide automation system, Valmet DNA, offers unique integration with process solutions including process analyzers. In addition, the delivery includes Valmet Industrial Internet solutions for Operator Training Simulator for the whole plant as well as basic hardware for connectivity for Performance Center services.

Information about the customers Lenzing and Duratex

The Lenzing Group headquartered in Austria is an international company of wood-based cellulose fibers. These high quality fibers are used in the textile industry, in the nonwovens industry for hygiene products and are also used in work and protective wear and in industrial applications. Dissolving wood pulp is subsequently processed from the raw material wood and marketed under the brands TENCEL™ for textile applications, VEOCEL™ for nonwovens and LENZING™ for special fiber applications in other areas and other products. The annual turnover of the Lenzing Group is above EUR 2,000 million.

Duratex is the largest producer of industrialized wood panels in the southern hemisphere. The company has three business areas: Wood, Ceramic tiles and Sanitary ware, metals, electric showerheads and faucets. The Wood division covers wood products and forestry, producing eucalyptus in more than 251 thousand hectares of forests. Duratex’s head quarter is located in the city and state of São Paulo and it has seven forestry units and 16 industrial facilities in Brazil and three production facilities in Colombia.

The state-of-the-art chloride removal system is designed by Veolia Water Technologies to optimize the recovery process in the industry of transformation of hardwood cellulose into pulp for textile fibers and fine paper making.

Rising paper consumption in Asia and growing global demand for more environmentally friendly fibers for the apparel industry are driving the increase in pulp making capacity to convert renewable fibers into a variety of fine paper products and viscose staple.

In tropical Indonesia, the Riau province is a major hub for the forestry industry and is home to the operations of the Asia Pacific Resources International Holdings Limited (APRIL) Group, the world’s second-largest producer of bleached hardwood kraft pulp.

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APRIL-owned Riau Andalan Pulp & Paper (RAPP) produces pulp of the highest purity at one of the world’s largest paper mills in Kerinci (Riau). As a result, RAPP performs pulping washing and cleaning steps which produce an organics-rich liquid stream. When this liquor is burned in the recovery cycle, it generates renewable power that helps the mill become energy self-sufficient. Over time, however, the process creates chloride and potassium accumulation which, if not tightly controlled, causes corrosion and boiler fouling increasing maintenance costs.

Hence, to prevent efficiency losses and boiler downtime, these chemicals need to be managed. To this end, Veolia will treat 550 tons per day of precipitator ash through its Enhanced Chloride Removal Process (ECRP™). Featuring best-in-class HPD® crystallization technology, this advanced system is designed to yield the best control of sodium recovery and chloride and potassium removal steps while minimizing energy consumption and related emissions.

“Once again, we are pleased to work with APRIL and build on the success we have achieved together over the years. Veolia’s chemical-saving HPD® technologies will be key components in the expansion of this important production site in Riau helping its pulping operations become more resource-efficient and sustainable” stated Jim Brown, CEO of Veolia Water Technologies Americas.

Through the continuous improvements in HPD® evaporation and crystallization systems, Veolia provides the safest, most-efficient solutions to pulp and paper mills around the world to further reduce their environmental impacts and create economic value derived from the responsible management of closed-loop industrial processes.

Veolia Water Technologies provides the complete range of services required to design, deliver, maintain and upgrade water and wastewater treatment facilities and systems for industrial clients and public authorities. The company's extensive technology portfolio features everything from online diagnostic solutions to evaporation and crystallization, energy-producing sludge treatment, state-of-the-art desalination, laboratory-grade water and mobile water services. By optimizing both processes and monitoring, Veolia Water Technologies helps clients reduce their water footprint while generating considerable savings in energy and chemical consumption. www.veoliawatertechnologies.com 

Veolia group is the global leader in optimized resource management. With nearly 169 000 employees worldwide, the Group designs and provides water, waste and energy management solutions which contribute to the sustainable development of communities and industries. Through its three complementary business activities, Veolia helps to develop access to resources, preserve available resources, and to replenish them.

In 2017, the Veolia group supplied 96 million people with drinking water and 62 million people with wastewater service, produced nearly 55 million megawatt hours of energy and converted 47 million metric tons of waste into new materials and energy. Veolia Environnement (listed on Paris Euronext: VIE) recorded consolidated revenue of €25.12 billion in 2017. www.veolia.com 

source: www.veoliawatertech.com/asia/

Big data has been a buzzword for a few years now, as computer capabilities increase and data acquisition grows.

In the manufacturing sector, industries are seeing massive increases in the amount of data coming from their production lines, thanks to Industry 4.0 technology that makes use of machines embedded with sensors and wirelessly connected to the cloud for machine-to-machine (M2M) and Internet of Things (IoT) communication.

However, along with these massive amounts of data comes the need to effectively manage them, and this links directly to the concept of data as an asset.

2020 01 28 140846Data as an Asset explained

A data point is only a number which, considered in isolation, may have no value, and the same reasoning can also be extended to an entire data set. The concept of Data as an asset that implies that data acquire value when put in relation to other data and to business operations. In other words, these data, when analyzed together, increase their total value by helping inform business and factory decisions and strategy more effectively than they could do if considered by themselves

Read more: How to set up data driven production processes in tissue & nonwovens industries

How to manage Data as an Asset

Traditionally, a tissue and nonwovens company collected data that would provide a view into the productivity and profitability of a production line. This might be data such as costs, the production volume and the demand for the product.

Now, thanks to the Industry 4.0, the companies are provided with detailed machine data (speed and tension) and environmental data (temperature and humidity).

  • The first step in managing data as an asset is to combine the traditional data with the operational ones to come up with a complete picture of the operations and the productivity.
  • The next step is to ensure that all data is accessible via a machine-and software-independent platform. This platform must provide features such as artificial intelligence (AI) and machine learning to analyze the data and recognize patterns, thanks to which the companies can enjoy fully automated adjustments to the production processes and predictive maintenance scheduling.
  • Finally, these data must be accessible to and well-managed by everyone at the company. It should be everyone’s responsibility to ensure these data are used to balance corporate operations for maximum profitability. This allows every worker at the company, from the top down, to optimize the data for their needs, while still recognizing the needs of the company as a whole.

Read more: How to manage data governance in an Industry 4.0 system

Using Data as an Asset for intelligent collaboration

With Industry 4.0 technologies and proper management of data as an asset, tissue and nonwovens companies can ensure intelligent collaboration between the production line and the converting line. Each machine on these two lines, as we previously said, will be outfitted with sensors capable of transmitting operational data in real-time, and all of these data will flow to a single platform where they can be integrated and analyzed by AI.

The advantage of this setup is that the AI will be able to detect anomalies and small changes in the operation of any single machine or one of its part that might disrupt the flow of production and converting.

An example might be when the master roll rewinder is not moving at a speed fast enough to accommodate the rolls coming off the production line. The data will reflect this inconsistency and the speed of either the toilet roll rewinder or the production line will be adjusted automatically by the AI program.

Another example could be when there is a faulty part in the paper log cutter, resulting in the need to take the converting line offline. The data analysis will result in the automatic redirection of the roll coming off the production line to a functioning converting line.

Read more: How to measure tissue and nonwovens mill machinery performance with real time analytics

A.Celli Digital Solutions for Data as strategic Asset

A.Celli Digital Solutions has been designed to fully and automatically manage data as an asset. This cloud-based platform provides:

  • a distributed real time monitoring system called “Machine Monitoring”;
  • a business intelligence platform called “Efficiency 4.0”;
  • a Product Passport methodology called “iREEL”. 

iREEL is particularly important when it comes to intelligent collaboration between the production and converting lines, because it provides a fully integrated framework that enables communication between the data that comes from the different machines on each line and the data coming from industrial and business applications.

Data is no longer something companies can afford to collect and store somewhere they will gather virtual dust, but they must be viewed as an asset that can be used to positively impact production and corporate operations. In the tissue and nonwovens industry, data as an asset is a critical component in ensuring the smooth flow of product from the production line to the converting line and the optimal efficiency of the production process.

For more information about one of the best Industry 4.0 solution that can boost productivity on your tissue and nonwovens production line, download our free eBook "A.Celli Digital Solution: Your Fellow Traveller on Your Journey Through Industry 4.0"!

Hayat Kimya Alabuga TM 4 sets a new world record by using Voith’s QualiFlex CrownT sleeve on the ViscoNip application in Russia. The paper mill produces virgin fiber-based toilet paper, paper napkins and kitchen towels.

  • New sleeve world record with a running time of 661 days
  • Voith’s QualiFlex extends its leading position for shoe press applications

In December 2017, a QualiFlex CrownT sleeve was installed at Hayat Kimya TM 4 maintaining stable machine production during the entire sleeve lifetime. Voith’s QualiFlex CrownT sleeve reached a world record life of 661 days and 473,810,000 nip cycles. The former world record sleeve on such an application was set in China, achieving 585 days.

Voith’s QualiFlex CrownT sleeve.Voith’s QualiFlex CrownT sleeve.

The customer was very satisfied with the result. “My congratulations to the whole Voith team for this excellent result and belt quality. My personal thanks to Voith for the support and proper service during the runtime of this belt,” says Mr. Lenar Safin, Tissue Production Chief at Hayat Kimya.

Press sleeves for every requirement
With QualiFlex CrownT, Voith offers a superior press sleeve for tissue shoe press applications which enables stable machine operating conditions and optimum efficiency. Selected polyurethane materials ensure the highest possible abrasion resistance under challenging high temperature conditions.
Compared to the conventional press sleeves, QualiFlex CrownT is especially designed for tissue applications. Conventional press sleeves show strong reactions to harsh conditions, and often suffer from hydrolysis, higher wear and reduced void volume.

Hayat Kimya Site in Tatarstan, Russia.Hayat Kimya Site in Tatarstan, Russia.

With Voith’s QualiFlex CrownT, open area and void volume can be designed exactly to the customer’s needs. The special heat-resistant material formulation makes this press sleeve the perfect choice for very demanding applications.
Voith QualiFlex press sleeves extend the leading position for shoe press applications in the tissue sector.

About the Voith Group
The Voith Group is a global technology company. With its broad portfolio of systems, products, services and digital applications, Voith sets standards in the markets of energy, oil & gas, paper, raw materials and transport & automotive. Founded in 1867, the company today has more than 19,000 employees, sales of € 4.3 billion and locations in over 60 countries worldwide and is thus one of the larger family-owned companies in Europe.

The Group Division Voith Paper is part of the Voith Group. As the full-line supplier to the paper industry, it provides the largest range of technologies, services, components and products on the market and offers paper manufacturers solutions from one single source. The company’s continuous stream of innovations takes papermaking to the next level and facilitates resource-conserving production. With its Servolution concept, Voith offers its customers tailored service solutions for all sections of the production process. Voith Papermaking 4.0 ensures that equipment is optimally connected, while the secure use of generated data enables paper manufacturers to improve plant availability and efficiency.

International pulp and paper producer Sun Paper has selected technology leader ABB to fulfil two orders for its facilities in Laos and Shandong, China. The first order comprises new drives for the company’s paper machine 1 (PM1) and paper machine 2 (PM2) at its Laos mill, while the second includes a synchronous motor, motor starting equipment, excitation protection control and process drives for chemical pulp production at its plant in Shandong, eastern China.

The first order forms part of the second phase of Sun Paper’s Laos project that includes two advanced packaging paper production lines (PM1 and PM2) with annual production capacity of 800,000 tons. ABB will provide its highly-efficient, distributed PMC800 multi-drive control system with total installed capacity of 41,000KW and more than 120 drive points for both paper machines, which are 7.3m and designed for speeds of 1200 m/minute. For the chemical pulp project in Shandong, ABB will provide two sets of 14 MW synchronous motors, medium voltage motors and a drive system.

ABB wins drives order for two different Sun Paper projects in China and LaosABB wins drives order for two different Sun Paper projects in China and Laos

For both projects, ABB’s scope of supply includes its most advanced PMC800 drive system and ABB Ability™ System 800xA distributed control system (DCS), featuring stable and easy operation, abundant information access and low maintenance requirements. ABB’s drives incorporate unique Direct Torque Control (DTC) technology, ensuring efficient production of high torque at low speeds.

“Competition for these prestigious projects was understandably fierce, but by optimizing our technical proposal and demonstrating our success with previous projects of a similar scope and scale, our China Pulp and Paper team was able to provide the best solution,” said YueMing Liu, Pulp and Paper Industry lead for China at ABB. “ABB also provided the automation solution for phase 1 of the Laos Project, which won the Modern Manufacturing 2018 Solution Excellence Award. By establishing mutual trust in multiple projects with Sun Paper, we hope to provide a solid foundation for our future relationship.”

About the Sun Paper Laos Project
Sun Paper invested in the Laos Project in response to the Belt and Road initiative promoted by the Chinese government, which encourages development along a former trade route that links China with other economies across Asia, Europe and Africa. Phase 1 of the project had a massive undertaking—a 400K ton chemical pulp project that covers the complete process of pulp production, alkaline recovery, pulp board machines, biomass furnaces, and chemicals. Phase 2 will continue to enrich Sun Paper’s product types, increase product grade, promote the product structure upgrading, greatly improve the comprehensive strength and core competitiveness to further consolidate its leading position in the paper making industry of China.

ABB (ABBN: SIX Swiss Ex) is a pioneering technology leader with a comprehensive offering for digital industries. With a history of innovation spanning more than 130 years, ABB is today a leader in digital industries with four customer-focused, globally leading businesses: Electrification, Industrial Automation, Motion, and Robotics & Discrete Automation, supported by its common ABB Ability™ digital platform. ABB’s market leading Power Grids business will be divested to Hitachi in 2020. ABB operates in more than 100 countries with about 147,000 employees.

Toscotec will showcase its efficient, paper machine rebuilding solutions at PaperWeek Canada 2020 Booth 8, from February 4 through 6, in Montreal.  

2020 01 28 085118

On February 5 at 9:00 am, Fabrizio Charrier, Toscotec Paper & Board Area Sales Manager, will present “Toscotec’s dryer section rebuild: the in-depth analysis of case histories”. This presentation illustrates how TT SteelDryer and Toscotec’s beginning-to-end support ensures the successful outcome of dryer section rebuilds including the increase of production and the improvement of the sheet moisture profile. 

TT SteelDryers guarantee a superior drying rate and a long operating life. Compared with cast iron cylinders, TT SteelDryers provide up to 30% more drying capacity.  This is based on their higher heat transfer rate and wider drying face length, which dries a larger sheet width considering the same cylinder length, thereby increasing productivity. Toscotec currently counts more than 1,300 installed TT SteelDryers globally. 

Voith is adding three new products to its range of Measurement and Diagnostic Services. MobiLab is a mobile analysis laboratory to investigate and optimize stock quality on site. With the SpeedUp Certificate, Voith is examining the possibilities for paper manufacturers to operate their paper machines above the original design speed, in consideration of the machine-dynamic behavior. And 3D Scan produces high-precision digital images of the current condition of the production facilities.

As part of its Servolution range, Voith’s Measurement and Diagnostic Services are tailored specifically to the requirements of the paper industry. Plant operators benefit from the mechanical and technological expertise of a full-line supplier and service experts with more than 10 years industry experience on average. This means that Voith’s Measurement and Diagnostic Services not only ensure smooth operation but also improve the economic efficiency of the system.

“Through our Measurement and Diagnostic Services, we are offering paper manufacturers tailored solutions that are state-of-the-art,” explains Stefan Natterer, Head of Measurement and Diagnostic Service at Voith. “And we are continually adding new technologies and services like MobiLab, SpeedUp Certificate and 3D Scan to our range.”

Through its Measurement and Diagnostic Services, Voith offers customized solutions for optimizing paper production.Through its Measurement and Diagnostic Services, Voith offers customized solutions for optimizing paper production.

MobiLab – mobile laboratory to optimize stock preparation
In the event of quality and process fluctuations in the paper production process, plant operators face the challenge of identifying the triggers. Generally, this has to be determined by analyzing and evaluating a large number of stock samples. However, as only very few paper manufacturers maintain a well-equipped wet laboratory on site, large numbers of samples must be sent to designated institutes for testing. This not only involves a significant logistical effort but is generally also very time-consuming and costly. Due to the complex process necessary to preserve the samples, valuable results may be falsified or even rendered worthless.

The solution: the Voith MobiLab – a fully equipped mobile containerized wet laboratory for the analysis of typical problems in the stock preparation process, from fiber loss to issues with chemicals mixing. When trying to identify the causes, Voith experts on site can utilize all the usual analysis processes.

In addition to laboratory measurements in the MobiLab, Voith also offers the Wet End Process Analysis Package. Thanks to a combination of various measurement techniques (pressure pulsation, stock density, air content, online paper transmission and offline Tapio analysis) the basis weight stability profiles of the paper can be determined, for example. Using a paper sample database and best practices, the current status and any faults can be identified quickly and efficiently and action initiated to rectify them. In addition, the MobiLab can be used when trialing new paper grades or qualities in the course of machine tests on actual customer equipment – to get the best possible results from what are generally expensive field tests.

The Voith MobiLab is a fully equipped wet laboratory for analyzing stock samples directly on site.The Voith MobiLab is a fully equipped wet laboratory for analyzing stock samples directly on site.

SpeedUp Certificate – verifying speed increase options
In theory, the operating speed of a paper machine can be increased by installing a new, technologically improved component, and as a result the cost efficiency of the entire manufacturing process improved. But what if the original maximum design speed of the paper machine is lower than the potential speed of the new component?

With the Voith SpeedUp Certificate, companies can have an audit performed on the entire paper machine to determine whether the design of the machine components is suitable for a future operating speed that is higher than the original design speed. For example, machine dynamic limitations such as vibrations, critical speeds, drive design, condition of existing components and technological process considerations are checked as necessary. Unsuitable components are identified, and the measures required to increase the operating speed are indicated. Such measures could include, for example, the replacement of unsuitable guide rolls or adding bracing to the machine frame.

Following successful completion of a speed-up inspection by Voith, the machine gets a “Type Design Speed Certificate” that defines a new maximum design speed of the analyzed components and machine groups. This gives paper manufacturers a reliable basis to work with before they increase the production speed of their machine.

: With the 3D Scan, Voith experts on site can create a digital spatial image of a machine and its environment.: With the 3D Scan, Voith experts on site can create a digital spatial image of a machine and its environment.

3D Scan – spatial image of actual machine accurate to the millimeter
Paper mills change over time, for example as a result of upgrades and the installation of new components. Often, however, this is not documented in the design drawings, which can cause complications in the event of further rebuilds.

With the 3D Scan, the Voith experts on site can create a digital spatial image of a machine and its environment, and in this way record the actual situation of the machine to an accuracy of one millimeter at a scanning distance of ten meters and a maximum scanning range of 360 meters. The real data obtained can be stored as point clouds in various formats and then processed to be used as a template for a rebuild project, installation check or for measurements on your desktop. Point cloud data can be combined with CAD data to produce a machine model including all cable and piping. The spatial review in the 3D CAD system with automatic collision check reduces the likelihood of complicated rework and adaptations on site.

Attila Bencs, General Manager at Hamburger Hungaria Ltd., views this as a distinct advantage: “When converting the pulpers at our plant in Dunaújváros, the 3D Scans had already given us the most accurate information in advance on the spatial conditions on site. The improved visualization was beneficial to both all project participants and machine operators,” Bencs says, summing up the extremely useful deployment of the 3D Scan by Voith, and adding: “This saved us a lot of time and work for the rebuild.”

Valmet will supply a board machine rebuild to Umka Cardboard Mill in Serbia. The main target of the rebuild is to increase the customer’s production capacity. The start-up of the rebuilt paper machine PM 1 is scheduled for the second half of 2021.

The order is included in Valmet's orders received of the fourth quarter 2019. The value of the order will not be disclosed. The total value of an order of this type is typically around EUR 15-20 million.

"This rebuild is one of the most important strategic decisions we have made in the course of 80 years long history of the mill. We are pleased that this project is going to be completed by Valmet, a global leader in the supply of process technology in the paper industry. I strongly believe in the success and bright future of Umka Cardboard Mill, with planned capacity of over 200,000 tonnes, further quality improvements and wider product portfolio,” says Milos Ljusic, Managing Director of Umka.

"The co-operation between Valmet’s and Umka’s teams has been excellent. Together, we built up a solution which will help Umka increase production capacity and improve their end product quality," says Pekka Turtinen, Senior Sales Manager at Valmet.

Umka’s and Valmet’s teams at the Umka 80-year anniversary celebration. From left: Kari Räisänen (Valmet), Milos Ljusic (Umka), Jadranka Priljeva (Umka), Staniša Lukić (Umka), Nikola Pejović (Umka) and Pekka Turtinen (Valmet)Umka’s and Valmet’s teams at the Umka 80-year anniversary celebration. From left: Kari Räisänen (Valmet), Milos Ljusic (Umka), Jadranka Priljeva (Umka), Staniša Lukić (Umka), Nikola Pejović (Umka) and Pekka Turtinen (Valmet)

Improved production capacity

Valmet's delivery will include major changes in the wet end of the paper machine PM1 with broke collection, approach flow system and three OptiFlo Foudrinier headboxes to meet the growing productivity and quality requirements of high-quality board machine, as well as an OptiFormer Multi forming section with multiple foudriniers and modifications in the press section.

The delivery will also include an OptiCoat Layer curtain coating station with supply system and an OptiDry Turn air dryer and an OptiWin Drum two-drum winder. Related spare parts and paper machine clothing for start-up and Valmet DNA Machine Controls System will also be included. A two-year Valmet Performance Center on-demand expert support will further help Umka to reach its targets.

The 3,700-mm-wide (wire) PM1 will produce white lined chipboard grades with a basis weight range of 160-450 g/m2. The design speed of the new parts will be 440 m/min. The daily design capacity will be approximately 620 tonnes.

Information about the customer Umka

Umka Cardboard Mill has been a part of KappaStar Group since its privatization in 2003. Mill’s production capacity is currently 130,000 tonnes per year. Umka exports over 80% of its production to over 30 European countries. The most important export markets are Poland, Hungary, Romania and Russia. Umka’s cardboard is widely used in the manufacturing of cardboard packaging for the food, confectionery, pharmaceutical, chemical, tobacco, textile, and automotive industries, as well as for spare parts production within the machine industry. It is also used for lamination in the manufacture of transport packaging.

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