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Energy savings and high product quality in Metsä Board Kyro: goals achieved with Energy Recovery System and GemDryer® Infrared drying system

Metsä Board Kyro produces coated folding boxboard for packaging. It was decided to replace the existing gas infrared equipment on board machine n°1 with the goals of higher reliability, higher efficiency and significant energy savings.  The start-up took place in September 2017.

Metsä Board and Bekaert Solaronics share a long history of partnership and Metsä Board counted on the experience of Bekaert Solaronics in the upgrade and optimization of non-contact drying systems.

Bekaert Solaronics supplied a 4-row GemDryer® infrared drying system equipped with Gem9E emitters. The exhaust air from the GemDryer® is used as make-up air for the existing air-dryer via the ERS link. This reduces the gas consumption of the air dryers and thereby the energy efficiency of the total drying is significantly improved as well.

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Significant energy savings and optimal product quality

Energy savings guarantees of 300 kW have been achieved while keeping the good drying strategy from quality point of view. The combination of the new Bekaert Solaronics Gem9E emitters and the ERS energy link implemented after the coating station increases the efficiency while keeping the same drying capacity. As a result, the cost of drying is decreased by 30% for the coating station compared to the situation before the rebuild.

The solutions meets also the customer needs in terms of flexibility, reliability and ease of maintenance.
According to Petri Huiko, Production Manager in Kyro mill, all the goals have been fulfilled: “we are very satisfied by the performance of the Bekaert Solaronics solution”.

About Metsä Board
Metsä Board is a leading European producer of premium fresh fibre paperboards including folding boxboards, food service boards and white kraftliners. Metsä Board, part of Metsä Group, has approximately 2,350 employees and totals €1.8 billion of combined sales.
Metsä Board Kyro mill produces high-quality fully coated folding boxboard for packaging and graphic applications.

About Bekaert and Bekaert Solaronics
Bekaert is a world market and technology leader in steel wire transformation and coating technologies. We pursue to be the preferred supplier for our steel wire products and solutions by continuously delivering superior value to our customers worldwide. Bekaert (Euronext Brussels: BEKB) is a global company with almost 30 000 employees worldwide, headquarters in Belgium and €4.4 billion in annual revenue. Founded in 1967, Bekaert Solaronics supplies customized drying and heating systems based on gas and electrical infrared technology to a wide range of industries. Today, more than 1 000 systems have been installed worldwide. The company also provides maintenance services and is available to assist on upgrades or improved energy efficiency of existing systems.

Published in European News

Bekaert Solaronics received an important order from Bellmer as part of their coater machine upgrade contract with Kyiv CPM in Ukraine. The drying upgrade consists of installing three hoods UniDryer® V3 followed by air bars after each of the three coating stations; including a new coating unit delivered by Bellmer.

Kyiv CPM is carrying out a challenging investment program in the cardboard plant to upgrade the coater machine. The main objectives are to increase the speed of the coater up to 400m/min, install a new coating unit and modernize the coat drying equipment. The project includes reducing the steam consumption and improving the quality of the coated board. First step of the installation is scheduled to take place in April 2018.

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Energy economy and quality are guaranteed by the UniDryer® V3 systems that reach a high energy efficiency level thanks to the combination of the superior performance Gem9E emitters and the improved convection. These features result in a fast heat-up, a high evaporation rate and ultimately in better product quality. The set of blowing air bars will bring additional energy and mass transfer to increase overall system efficiency and avoid sticking of coated surface at paper roll contact. They are fed directly by the exhaust air from the UniDryer® systems, optimizing the operating costs.

About Gebr. Bellmer GmbH Maschinenfabrik

Located in Nierfen, Bellmer is a specialist starting from the planning up to the turnkey implementation of machines and plants for the manufacturing of paper and board. The company supplies from individual parts to complete machines for the paper industry. Bellmer has been working for the pulp and paper industry since 1842.

About Kyiv CPM

PJSC Kyiv Cardboard and Paper Mill, part of the Austrian Pulp Mill Holding, is one of the biggest enterprises in Europe in cardboard and paper production. The mill accounts for about 30% of the total cardboard and paper produced in Ukraine. The main raw material used for cardboard and paper production is recycled paper. The cardboard plant produces coated and uncoated cardboard and containerboard, including fluting for corrugated products with a total output of 240 000 tons per year.

About Bekaert and Bekaert Solaronics

Bekaert (www.bekaert.com) is a world market and technology leader  in  steel  wire transformation and coating technologies.

We aim to be the preferred supplier of our steel wire products and solutions by continuously delivering superior value to our customers worldwide. Bekaert (Euronext Brussels: BEKB) is a global company with 30 000 employees worldwide, headquarters in Belgium and more than € 4 billion in annual revenue.

Founded in 1967, Bekaert Solaronics supplies customized drying and heating systems based on gas and electrical infrared technology to a wide range of industries. Today, more than 1 000 systems have been installed worldwide. The company also provides maintenance services and is available to assist on upgrades or improved energy efficiency of existing systems.

Published in European News

Cartiera di Momo produces recycled coated paperboard. Market demand for increased quantity and higher quality drove Cartiera di Momo to decide in late 2015 to replace the existing 30 years old Bekaert Solaronics infrared systems with the goals of increasing the machine speed, reducing the gas consumption as well as improving the quality.

Bekaert Solaronics supplied four gas infrared systems UniDryer® V3 followed by sets of air bars after each of the four coating stations. The Energy Recovery Concept was again applied to this project with the air bars sets directly fed by the exhaust hot air coming from the UniDryer® V3 systems. This concept allows even more energy savings!  The start-up took place in August 2016.

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Huge energy savings of over 30%

All the goals of the project have been met. Implementation of air bars with ERS has led to a drastic decrease of gas consumption. “Almost immediately natural gas consumption dropped drastically” says M. Ugo Dell'Aria Burani, Managing Director in Cartiera di Momo. “Only ten months after the installation, savings of over 30% were measured with natural gas consumption of approximately 9.9 standard cubic meters per ton of production vs the previous 13 standard cubic meters per ton.”

UniDryer® V3 allows machine speed to increase and brings higher quality

The project’s goal was to increase the machine speed while keeping or improving the quality requested by the end customers. Thanks to its power and flexibility, the UniDryer® V3 achieves optimal quality control: the infrared parts of the systems allow reaching the gel point in a fast time lapse and the convective parts of the systems permit reaching the average moisture needed for the application.

Cartiera di Momo quality engineers measured and compared the offset printing before and after the machine modification. According to M. Ugo Dell’Aria Burani, the difference is noticeable: “the optimal drying of all coating layers gave considerably improved print quality”.

The target of the machine speed increase has also been achieved: “the new dryer systems allowed us to attain faster machine speed” says M. Ugo Dell’Aria Burani.

Cartiera di Momo and Bekaert Solaronics, a true and long-term partnership

The over 30-year partnership with Bekaert Solaronics started in 1985: Cartiera di Momo was the first Bekaert Solaronics customer in Italy to install infrared drying systems after each of the three coating stations.

In 1987, a new Bekaert Solaronics system was added to dry the back side treatment. This last system was upgraded in 2012 with Gem9 emitters in order to enhance drying capacity.

About Cartiera di Momo S.p.A

Established in 1963, Cartiera di Momo S.p.A. specializes in the production of coated multilayer cardboard packaging made with recycled fibers. The paper mill in Momo (near Novara) occupies an area of approximately 46,000 sqm and is equipped with a 262 cm wide continuous machine. Annual production capacity is 80,000 tons, from 270 gr/ sqm up to 600 gr/ sqm.

About Bekaert Solaronics

Founded in 1967, Bekaert Solaronics supplies customized drying and heating systems based on gas and electrical infrared technology to the paper and board industry. Today, more than 1 000 systems have been installed worldwide. The company also provides maintenance services and is available to assist on upgrades or improved energy efficiency of existing systems. More information on http://drying.bekaert.com.

If you want to know more on the advantages of infrared drying systems for the paper and board industry, contact Mr Cédric Dehouck, Market Manager Bekaert Solaronics: cedric.dehouck@bekaert.com, Telephone: +33 3 20 10 59 49

Published in European News

Bekaert Solaronics will supply Metsä Board Kyröskoski mill with a GemDryer® system for coat drying on their BM1, linked with one Energy Recovery System (ERS).

lgo bekaertThe GemDryer® infrared system replaces existing gas infrared equipment. The new drying system from Bekaert Solaronics offers higher input power, higher efficiency and helps to decrease the total running costs.

Bekaert Solaronics and Metsä Board share a long history of partnership and Metsä Board counted once more in the considerable experience of Bekaert Solaronics in the upgrade and optimization of non-contact drying systems. In this new project, the GemDryer® together with Gem9E emitters will increase the drying performance by 20%. They will also meet the customer needs in terms of high power density, high efficiency, flexibility and ease of maintenance.

In addition, the combination of the infrared drying system and ERS ensures significant energy savings by recirculating the final exhaust from the IR hood into the existing air dryer.

About Metsä Board
Metsä Board, previously known as M-Real Corporation, is a leading European producer of premium fresh fibre paperboards including folding boxboards, food service boards and white kraftliners. Metsä Board, part of Metsä Group, has approximately  2 500 employees and totals €1.7 billion of combined sales.
Metsä Board Kyro mill produces high-quality fully coated folding boxboard for packaging and graphic applications.

About Bekaert and Bekaert Solaronics
Bekaert is a world market and technology leader in steel wire transformation and coating technologies. We pursue to be the preferred supplier for our steel wire products and solutions by continuously delivering superior value to our customers worldwide. Bekaert (Euronext Brussels: BEKB) is a global company with almost 30 000 employees worldwide, headquarters in Belgium and €4.4 billion in annual revenue. Founded in 1967, Bekaert Solaronics supplies customized drying and heating systems based on gas and electrical infrared technology to a wide range of industries. Today, more than 1 000 systems have been installed worldwide. The company also provides maintenance services and is available to assist on upgrades or improved energy efficiency of existing systems.

Published in European News

Bekaert Solaronics supplied Ahlstrom-Munksjö Arches with two 2-rows UniDryer® V3 hoods for drying of abrasive paper base after size press on its PM4.

Ahlstrom-Munksjö Arches (formerly known as Arjowiggings Arches) is the oldest customer of Bekaert Solaronics. The first IR drying system was installed in 1966 on the PM5. Since then, Ahlstrom-Munksjö Arches continued to count on Bekaert Solaronics for all its projects as seven infrared drying systems have been installed in the paper mill. 

2017 06 06 103343The main objectives of the new UniDryer® V3 are to dry efficiently the paper coats and achieve guaranteed moisture at the inlet of sizer 2.

The UniDryer® V3 is a very compact system in which high performance gas infrared emitters are alternated with high temperature and velocity air nozzles without requiring a heat exchanger or an external gas burner. These features result in a fast heat-up, a high evaporation rate and ultimately in better product quality.

About Ahlstrom-Munksjö Arches SAS
The Arches mill was founded in 1492. Acquired by the international paper group Munksjö in 2011, the Arches paper mill employs today 470 people and possesses a wide range of machinery, including 7 paper-making machines and three rotary presses.  Ahlstrom-Munksjö Arches produces decor papers, abrasive backing papers, fine art papers and papers for art publishing.

About Bekaert and Bekaert Solaronics
Bekaert is a world market and technology leader in steel wire transformation and coating technologies. We pursue to be the preferred supplier for our steel wire products and solutions by continuously delivering superior value to our customers worldwide. Bekaert (Euronext Brussels: BEKB) is a global company with almost 30 000 employees worldwide, headquarters in Belgium and € 4.4 billion in annual revenue. Founded in 1967, Bekaert Solaronics supplies customized drying and heating systems based on gas and electrical infrared technology to a wide range of industries. Today, more than 1 000 systems have been installed worldwide. The company also provides maintenance services and is available to assist on upgrades or improved energy efficiency of existing systems.

Published in European News

Bekaert Solaronics will supply Hangzhou Dongda Paper Co. Ltd with a 3-rows infrared GemDryer® and one Energy Recovery System (ERS) for coat drying on its PM2. This order comes just after the installation in 2016 of two GemDryer® and two ERS after-press and existing coater on the PM1 of Zhejiang Dongda Paper Co., Ltd.  Dongda Paper manufactures coated recycled board.

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Bekaert Solaronics has a long-lasting experience in the optimization of non-contact drying systems. The combination of the GemDryer® with the ERS will help to increase the machine speed-up after press and coating stations and realize significant energy savings by using directly the exhaust from the infrared dryers as an energy source for the air dryer.

Moreover, thanks to their compactness and coupled with the high performance Gem12+ emitters, the GemDryer® systems meet the customer needs in terms of high power density, drying flexibility and efficiency and ease of maintenance.

About Zhejiang Dongda Paper Co.,Ltd
Zhejiang Dongda Paper Co. Ltd is a major producer of coated white cartonboard and paper in Zhejiang Province. The company was founded in 1999, and its annual production capacity is 400,000 tons.

About Hangzhou Dongda Paper Co., Ltd
Founded in 2003, Hangzhou Dongda Paper Co., Ltd is a top-grade coating white paper board’s manufacturer located at Spring River Street, Fuyang City in China. The paper mill produces duplex board with white or grey back and coated duplex board. Covering an area of more than 70,000 square meters, the annual production capacity is more than 100,000 tons.

About Bekaert and Bekaert Solaronics
Bekaert is a world market and technology leader in steel wire transformation and coating technologies. We pursue to be the preferred supplier for our steel wire products and solutions by continuously delivering superior value to our customers worldwide. Bekaert (Euronext Brussels: BEKB) is a global company with almost 30 000 employees worldwide, headquarters in Belgium and € 4.4 billion in annual revenue. Founded in 1967, Bekaert Solaronics supplies customized drying and heating systems based on gas and electrical infrared technology to a wide range of industries. Today, more than 1 000 systems have been installed worldwide. The company also provides maintenance services and is available to assist on upgrades or improved energy efficiency of existing systems.

Published in Asian News

Bekaert Solaronics will supply a WebMate® infrared moisture profiling system to Twin Rivers Paper Company #5 Paper Machine. The system is equipped with 1 row of 39 electrical M2000 modules including 78 zones of fine profiling capability.

The partnership between Bekaert Solaronics and Twin Rivers started in 1994 with installation of a gas infrared drying system on #7 Paper Machine as part of a film sizer upgrade project.

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Today, Twin Rivers renewed its confidence in Bekaert Solaronics utilizing WebMate® technology providing improved moisture profiling capabilities to optimize paper quality with guaranteed peak moisture reduction.

The non-contact infrared drying system WebMate® assures optimal product quality, a high drying rate as well as a long lifetime use. The moisture profile correction is optimized thanks to the parabolic reflector technology that ensures a focused energy radiation only where it is needed.

About Twin Rivers Paper Company

Launched officially in April 2010, Twin Rivers Paper Company acts as a specialty papers business, with fully integrated operations comprised of a pulp and energy complex in Edmundston, a paper mill in Madawaska as well as a lumber mill located in Plaster Rock, New Brunswick. On December 2016, Twin Rivers paper mill acquired the four paper mills assets from the Burrows Paper Corporation.  The transaction supports the strategic evolution of the group to grow in the lightweight packaging and technical specialty papers.

About Bekaert and Bekaert Solaronics

Bekaert is a world market and technology leader in steel wire transformation and coating technologies. We pursue to be the preferred supplier for our steel wire products and solutions by continuously delivering superior value to our customers worldwide. Bekaert (Euronext Brussels: BEKB) is a global company with almost 30 000 employees worldwide, headquarters in Belgium and € 4.4 billion in annual revenue. Founded in 1967, Bekaert Solaronics supplies customized drying and heating systems based on gas and electrical infrared technology to a wide range of industries. Today, more than 1 000 systems have been installed worldwide. The company also provides maintenance services and is available to assist on upgrades or improved energy efficiency of existing systems.

Published in North American News

Bekaert Solaronics supplied Kingdecor (Zhejiang) with two hoods of 6-rows infrared UniDryer® for drying of laminating papers on its Paper Machine 1.

Thanks to its high energy efficiency and flexibility, the UniDryer® will achieve a uniform total drying after the size press while maintaining the high-quality levels of the specialty paper.

lgo bekaertThe system UniDryer® consists of high velocity air flotation nozzles for an optimal convective heat transfer, high performance gas infrared emitters and integrated blowing fans. The combination of these features results in a fast heat-up, a high evaporation rate and ultimately in better paper quality. The system will be equipped with Gem12E, the latest generation of Bekaert Solaronics emitters that allow an increased drying efficiency by approximately 10 % compared to the regular Gem12 emitters.

About Kingdecor (Zhejiang) Co., LTD

Founded in 2004, Kingdecor (Zhejiang) Co., Ltd. is a joint venture established by Schattdecor AG from Germany and Zhejiang Special Paper Co. Ltd from China, with a registered capital of 32.6 M$. The paper mill has an annual production capacity of 180.000 tons of decor base paper, which is being exported to Asia, North America and Australia. 

About Bekaert and Bekaert Solaronics

Bekaert is a world market and technology leader in steel wire transformation and coating technologies. We pursue to be the preferred supplier for our steel wire products and solutions by continuously delivering superior value to our customers worldwide. Bekaert (Euronext Brussels: BEKB) is a global company with almost 30 000 employees worldwide, headquarters in Belgium and € 4.4 billion in annual revenue.

Founded in 1967, Bekaert Solaronics supplies customized drying and heating systems based on gas and electrical infrared technology to a wide range of industries. Today, more than 1 000 systems have been installed worldwide. The company also provides maintenance services and is available to assist on upgrades or improved energy efficiency of existing systems

Published in Asian News

Bekaert Solaronics to supply a GemDryer® infrared system at Greenpaper® (Formerly known as Productora de Papel S.A. de C.V.), Mexico

Bekaert Solaronics will supply Greenpaper with one infrared drying system GemDryer® after a rebuilt UMV twin HSM coater on its PM3.

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The paper machine PM3 manufactures 100% recycled clay-coated boxboard for folding box conversion. The Bekaert Solaronics GemDryer® addresses the paper machine’s flexibility needs and can be easily adapted to the different top coating dry weights.

Moreover, thanks to its compactness and unique design, coupled with the use of high performance Gem12E emitters, the system meets the customer needs in terms of high power density, ease of maintenance and low operating costs.  

About Greenpaper  
Greenpaper manufactures and sells clay coated folding box board both brown and white back, kraft and semi kraft paper for the packaging industry in Mexico. It offers folding carton, top liner, kraft liner, and corrugating medium products. Greenpaper (Formerly known as Propasa) was founded in 1943 and is based in San Nicolás de los Garza, Mexico.

About Bekaert and Bekaert Solaronics
Bekaert is a world market and technology leader in steel wire transformation and coating technologies. We pursue to be the preferred supplier for our steel wire products and solutions by continuously delivering superior value to our customers worldwide. Bekaert (Euronext Brussels: BEKB) is a global company with almost 30 000 employees worldwide, headquarters in Belgium and € 4.4 billion in annual revenue.
Founded in 1967, Bekaert Solaronics supplies customized drying and heating systems based on gas and electrical infrared technology to a wide range of industries. Today, more than 1 000 systems have been installed worldwide. The company also provides maintenance services and is available to assist on upgrades or improved energy efficiency of existing systems.

Published in South American News

Bekaert Solaronics will supply Cartiera di Momo with four infrared systems UniDryer® V3 followed by sets of air bars after each of the four coating stations on its PM1 recycled board machine.The Energy Recovery Concept is again applied to this project with the air bars directly fed by the exhaust hot air from the UniDryer® V3 systems. This concept allows even more energy savings! The installation of the systems is scheduled to take place during the 3rd quarter 2016.

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The partnership between Bekaert Solaronics and Cartiera di Momo started in 1986 with the installation of three gas infrared drying systems. The objective then was the non-contact drying of recycled board for boxboard C1S production. Today, Cartiera di Momo renewed its confidence in Bekaert Solaronics to replace the existing systems.

The benefits guaranteed to the paper mill by the UniDryer® V3 with integrated air bars are many:

  • machine speed will be significantly increased by 10 %;
  • gas consumption will be reduced by 36 %;
  • paper machine will be able to produce with 10 % more coat weight.

Moreover, thanks to the study carried out by Bekaert Solaronics, Cartiera di Momo has obtained a government subsidy for this project.

The UniDryer® V3 is a very compact system in which high performance gas infrared emitters are alternated with high temperature and velocity air nozzles. These features result in a fast heat-up, a high evaporation rate and ultimately in better product quality. Combined with the air bars, its efficiency is further improved and the gas consumption costs are optimized.

About Cartiera di Momo S.p.A

Established in 1963, Cartiera di Momo S.p.A. specializes in the production of coated multilayer cardboard packaging made with recycled fibers. The paper mill in Momo (near Novara) occupies an area of approximately 46,000 sqm. (of which 15,000 indoors), and is equipped with a 262 cm wide continuous machine. Annual production capacity is 80,000 tons, from 270 gr/ sqm up to 600 gr/ sqm. Current production includes grey back, manilla back (also for foodstuffs), coated white back and kraft back for foodstuffs.

About Bekaert and Bekaert Solaronics

Bekaert  (www.bekaert.com)  is  a  world  market  and  technology  leader  in  steel  wire transformation and coating technologies. We aim to be the preferred supplier of our steel  wire  products  and  solutions  by  continuously  delivering 

superior value to our customers worldwide. Bekaert (Euronext Brussels: BEKB) is a global company with 30 000 employees worldwide, headquarters in Belgium and € 4 billion in annual revenue. Founded in 1967, Bekaert Solaronics supplies customized drying and heating systems based on gas and electrical infrared technology to a wide range of industries. Today, more than 1 000 systems have been installed worldwide. The company also provides maintenance services and is available to assist on upgrades or improved energy efficiency of existing systems.

Published in European News
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