Displaying items by tag: voith
At the beginning of the year the new Tissue XcelLine TM 7 successfully started up at the Ejea de los Caballeros mill of Gomà Camps Consumer in Spain. The smooth startup of the tissue line was achieved thru the modern and efficient XcelLine concept.
“From stock on wire, to paper on reel it took only 30 minutes and the TM 7 speed-up is over achieving the planned start up curve. This was a great team performance.” José Ignacio González Sarasúa, Mill Manager of Gomà Camps Consumer S.L.U., confirms. “With passion and technological knowledge all the specialists involved teamed up, resulting in the remarkable success of TM 7 project.”
The TM 7 will have a working width of 2,800 millimeter and produces toilet paper and paper towels from 100 percent virgin pulp at a working speed of 2,000 meters per minute. Voith delivered the entire process line package to Gomà Camps: from BlueLine stock preparation and the double dilution approach flow system, the TM 7 XcelLine tissue machine, auxiliary equipment and system accessories all the way to the full automation, electrification and engineering. In addition, extensive services and replacement parts were included in the delivery, such as the entire clothing package, which is ideally coordinated with the requirements of shoe press technology. The entire new plant will be serviced 100 percent by Voith in an integrated maintenance and service concept.
Voith's XcelLine machines feature seamlessly coordinated and integrated components, technologies and services that enable fast start-up, excellent performance and high added value for its customers' investments. The scope of supply includes technologies that enable increased productivity and a lower use of energy and natural resources, including the MasterJet Pro T headbox, the modern NipcoFlex T shoe press, the EvoDry Y steel plate Yankee cylinder, the high-efficiency EcoHood T drying hood and the EcoChange T reel with automatic reel spool exchange. The NipcoFlex T shoe press contributes to the low energy consumption as well as to high super soft tissue qualities.
“With the integration in the Ejea site, the new TM 7 is a strategic step to strengthen our presence in the Iberian Peninsula and to deliver superior tissue quality with focus on sustainability,” explains Jordi Gomà-Camps, President of Gomà-Camps Group S.L., “From the very first minute of the project Voith was a true and reliable partner. With the latest Voith technologies installed in the process line, we ensure to have a competitive advantage for the best of our customers.”
Citing Voith capabilities and technology leadership, Green Bay Packaging has announced a landmark contract award that tasks Voith with providing a complete packaging production line. The new PM 4 will be installed at Green Bay Packaging’s location in Green Bay, Wisconsin, USA.
The family-owned paper and packaging producer Green Bay Packaging awarded Voith an order for a 300 inch (7.62 m) wide production line for testliner. The order includes an effluent treatment plant, BlueLine stock preparation, WEP, XcelLine paper machine with a design speed of 3,940 ft/min (1,200 m/min) and a VariFlex Performance winder. The package also includes paper machine clothing, a seven-year Total Roll Management contract for several machines, and Papermaking 4.0 products.
“Partnering with a family-owned company whose North American headquarters is in Appleton, Wisconsin, Green Bay Packaging is advancing its commitment to positively impacting the local economy and becoming a more sustainable producer. We appreciate Voith’s ability to get this advanced paper machine fully operational on a condensed timeline to help meet our customer demands,” said Will Kress, President and CEO of Green Bay Packaging.”
“Voith is proud of this historic project, and we are eager to continue our strong partnership with Green Bay Packaging,” said Martin Jauch, President Business Line Projects, Voith Paper North America.
The contract is of a breadth and scope previously unseen in the United States papermaking industry as a complete mill order has never before been sourced from a single manufacturer. Voith is the region’s only manufacturer capable of providing components for such a complete installation. The construction of the mill will be handled by Miron Construction Co, Inc., while KSH will supply the engineering, targeting a start-up in early 2021.
German papermaker Progroup AG has chosen Voith’s XcelLine machine concept for its flagship greenfield plant, Propapier PM 3 GmbH. The site is scheduled to open in 2020 in Sandersdorf-Brehna in the northwest of Leipzig.
- High performance XcelLine concept as decisive factor to receive contract
- New PM 3 will produce 750,000 tons of testliner and corrugated medium annually
- Start-up planned for 2020
Progroup contracted with Voith in July to deliver PM 3, a 10,000 millimeter wire width machine with an annual production capacity of 750,000 tons of testliner and corrugated medium. Voith will supply the feeding system, BlueLine stock preparation; reject system, paper machine with hood and process air system, hall ventilation, reel spool transport system and winder. The new machine will have an operating speed of 1,600 meter per minute.
Voith Paper was selected because of the outstanding performance of its XcelLine machine concept, as well as the proven BlueLine stock preparation, clothing and roll covers, VariFlex XL winder, and mechanical roll service.
Construction is scheduled to begin on the Propapier PM 3 plant in early 2019 with completion slated for the second half of 2020. Together with Progroup’s nearby facilities in Burg and Eisenhüttenstadt, the containerboard manufacturer will have a total annual production capacity of approximately 1.85 million tons.
About the Company
Voith Paper is a Group Division of Voith and the leading partner and pioneer in the paper industry. Through constant innovations, the technology group is continually optimizing the paper manufacturing process and paving the way for resource-saving production. Thanks to Papermaking 4.0, paper manufacturers can interconnect their equipment in an optimum way and increase their competitiveness through the effective and secure use of generated data. With Servolution, Voith Paper offers its customers tailored service solutions for all sections of the production process.
Voith is a global technology group. With its wide range of systems, products, services and digital applications, Voith sets standards in the markets for energy, oil & gas, paper, raw materials and transport & automotive. Founded in 1867, Voith today has more than 19,000 employees and earns 4.2 billion euros in sales. It has locations in over 60 countries and is one of the largest family-owned companies in Europe.
On 26 June, during ZELLCHEMING-Expo 2018, Voith introduced its new smart service package, Virtual Reality Solutions by Voith Paper. It offers paper manufacturers the opportunity to have their new machine modeled in virtual reality. This means that Voith customers can benefit from more transparency, efficiency and safety in paper production over the entire life cycle of the machine.
- New paper machine can be brought to life as early as the planning phase
- Better learning outcomes thanks to customized, interactive training programs for new and existing machines.
- Staff can acquire proficiency in a safe virtual environment
With Virtual Reality Solutions by Voith Paper, paper manufacturers can obtain a digital representation of their very own new machine within a matter of days. The system allows the machine to be brought to life before it is even built, either on a monitor or for an even more realistic experience using virtual reality goggles. In the planning phase this makes it much easier to configure the machine and develop infrastructure e.g. for stock preparation, buildings and access routes in the planning phase. Providing information to stakeholders is also a much simpler matter if the characteristics and functions of individual components and the entire machine can be represented realistically at any location in the world.
With Virtual Reality Solutions by Voith Paper effective use can be made of the time available prior to commissioning of the machine. Operators, maintenance crews and managers can acquire proficiency and familiarize themselves with the machine and those inner workings that are not directly accessible in real life. Virtual training programs allow personnel to acquire experience with the operation even though their paper machine is not yet running. Training in a virtual reality environment is about more than just visual perception; there is also a realistic noise backdrop and controls allow the user to move along the entire machine and execute certain hand actions. Much better learning outcomes can be achieved by addressing several sensory perceptions at once.
Virtual Reality Solutions by Voith Paper also ensures more efficiency during operation itself. Staff can practice maintenance activities in advance in interactive training scenarios. The training not only includes all work processes, which are simulated step by step with the necessary tools, it also focuses on occupational safety. For example, the replacement of a press sleeve or screen basket can be simulated and practiced in a safe virtual environment before the task is due to be performed at the machine. The routine acquired in this way then leads to shorter downtimes in real-life maintenance, a lower error rate and a reduced risk of workplace accidents.
With Virtual Reality Solutions by Voith Paper the company is taking its next step on route to Papermaking 4.0. “Our aim is to combine the potential offered by digitalization with the physical manufacturing process and in this way optimize paper production,” explains Thomas Holzer, President Business Line Projects Voith Paper. In doing so, Voith is once again offering its customers a tailored, intelligent service solution based on customer requirements that will significantly increase machine availability and process reliability
The new SmoothRun hydropneumatic damping bearing system for winders effectively reduces vibrations occurring during the winding process. Hydropneumatic damping allows for higher operating speeds and better winding results. Overall, capacity increases of up to 15 percent are possible. This compact upgrade solution is suitable for Voith and Jagenberg two-drum winders.
In conventional winders without special damping, vibrations can occur at higher production speeds for certain paper grades, and these vibrations can impair winding quality. To minimize the disruptive effect of vibrations during the winding process, the production speed and accelerations rates are reduced below the maximum capability of the winder. The solution: With SmoothRun hydropneumatic damping bearings from Voith the vibrations can be effectively reduced even at high speeds, allowing the equipment to operate at consistently high production speeds. At the same time, SmoothRun improves the winding results and reduces the overall mechanical stress on the machine.
Eliminating bottlenecks through capacity upgrades
Papier- und Kartonfabrik Varel (PKV) based in Lower Saxony, produces high-quality corrugating medium and testliner on its PM 5. Until now, the existing VariFlex M had to be run at a lower speed when producing paper grades sensitive to vibrations. The result is the winder could barely keep up with the production of the paper machine.
The purpose of the hydropneumatic damping bearings was to allow the winder to be operated at the maximum speed. “Following commissioning of the new bearing system we were able to reduce vibrations for all paper grades and increase speeds. We are currently optimizing the settings of the bearing system with intensive support from Voith,” explains Michael Wolff, Line Manager Equipment at PK Varel. “Following this optimization phase we assume that the speed of the winder can be increased. While further enhancements together with Voith are being made the winder can keep pace with the production of the PM 5,” says Wolff. Voith is helping the company achieve this goal by providing intensive support, e.g. by performing vibration measurements.
Wide range of winder upgrades
Voith offers a wide selection of upgrades enabling existing winders to be specifically adapted to today's requirements. For further information have a look at http://voith.com/winder-upgrades
TerraSpeed roll coatings from Voith have been used successfully for many years. The product range now has a new addition – TerraSpeed Supreme, featuring new and impressive design parameters that give the coating outstanding performance values. TerraSpeed Supreme is already being used successfully in more than 15 installations worldwide.
The new functional coating of TerraSpeed Supreme ensures very stable roughness values and outstanding sheet release. Thanks to its improved coating structure, TerraSpeed Supreme minimizes web breaks and can reduce the open draws. In addition, TerraSpeed Supreme enables much longer roll service lives.
Improved operational reliability at Hamburger Austria
There are already more than 15 successful installations operating worldwide. Voith customers are impressed by the new coating and have already placed follow-up orders. One such customer is renowned corrugated base board manufacturer Hamburger Pitten. Josef Krenn, Operations Director and Markus Ungersböck, Head of Mechanical Maintenance at Hamburger Pitten in Austria explain the success story of TerraSpeed Supreme as follows: “At Hamburger Austria we produce a high-quality, diverse range of corrugating medium, packaging papers and plasterboard on our PM 4 in Pitten. The sophisticated use of different raw materials, auxiliaries and operating supplies imposes stringent requirements on the Nipco-P roll, the key position in the press section. Following the expansion of our range of paper grades, performance and doctoring using standard ceramic roll covers for this position became very unstable. A greater number of web breaks, and in some cases even sheet passing under the doctor blade, as well as premature roll changes to re-machine surfaces after relatively short periods of service, were suddenly day-to-day occurrences.”
Voith engineers also recognized the challenge and helped the customer to select the best coating in combination with suitable doctor blades, as Krenn and Ungersböck confirm: “Since we have been using the new TerraSpeed Supreme from Voith Paper operation has been absolutely reliable at this critical position. In combination with Voith's SkyTerra S doctor blades, we have now been operating the unit for more than 2 years without interruptions and there has been no need to re-machine the roll surface. Web breaks originating from the Nipco-P roll have dropped significantly, sheet passing does not occur anymore and performance has been very stable over the entire operating time. The newly developed ceramic-coating TerraSpeed Supreme from Voith Paper has significantly improved our production but above all has made it operationally reliable again.”
Mondi impressed by TerraSpeed Supreme and SkyTerra S
Basically, the high wear resistance of Voith's TerraSpeed Supreme enables continuous doctoring at maximum load. The SkyTerra S blade with negative facet was specially developed for use with TerraSpeed Supreme. But the successful use of TerraSpeed Supreme at Hamburger Pitten is not an isolated example. The Mondi production facility in Frantschach, Austria, has also had a similar experience. Andreas Petschenig, maintenance engineer at the Mondi paper mill in Frantschach, is also impressed by the premium coating: “In Frantschach we produce high-quality sack kraft paper grades on our PM 6 and PM 8. The sophisticated use of materials including chemical auxiliaries and operating supplies means that the press has to meet fairly exacting production engineering requirements. For example, following the installation of the shoe press at the PM 6 the doctoring on the ceramic covers of the shoe press counter roll became unreliable. A greater number of web breaks, sheet passing, and high web draws were almost part of the daily routine, as were roll changes to re-machine surfaces after relatively short periods in operation.”
Thanks to the new coating there has been a considerable improvement in performance at Mondi in Frantschach as well, as Petschenig reports: “All these problems have been solved since we started using TerraSpeed Supreme from Voith Paper. In combination with the Voith doctor blades SkyTerra and SkyTop, the cover service lives could be substantially increased. There is no more sheet passing and web draws could be reduced. The newly developed ceramic cover TerraSpeed Supreme from Voith has considerably simplified our production.” In the meantime, TerraSpeed Supreme has also been running successfully for a year in the shoe press of the PM 5 at Mondi Steti.
Now that numerous other Voith customers have had a similar positive experience with TerraSpeed Supreme. Taylor designed doctor blades like SkyTerra S and SkyTop S can even enhance that high performance level.
The NanoSelect calender roll covers are tailored precisely to the specific requirements of a paper machine and as a result increase machine efficiency and paper quality. The desired roll cover properties are determined in consultation between a specialist from the paper manufacturer and the Voith sales engineer. The NanoSelect calender roll covers are configured using the specially developed product selector software.
Through the product selector and NanoSelect calender roll covers Voith is offering a new and unique way of satisfying individual customer requirements. Because the requirements that a roll cover needs to meet differ from paper machine to paper machine. This is why paper manufacturers often have to make compromises when selecting a cover. The new product selector software now allows paper makers to quickly and easily configure and procure the ideal roll cover for their specific application.
During a consultation with a sales specialist from Voith, the customer prioritizes their most important properties on the basis of parameters like wear or barring resistance. The consultant uses the software to put together the best technology for the roll cover. The result is a mixture of standard and application-specific components. This means that every cover is a one-off and is produced individually for the customer. Voith is grouping these customized roll covers under the new product name NanoSelect.
As NanoSelect roll covers are ideally matched to the requirements of a specific application, they facilitate the production of paper in the desired quality.
Regardless of the paper manufacturers' individual requirements they can use the product selector and NanoSelect to configure their roll covers in an ideal way to obtain the desired properties. For example, if a paper producer has a barring problem in a SoftNip calender despite low loading, a new module in NanoSelect will help reduce this. Another example is the gloss module, which results in a higher gloss and can potentially allow for the adaptation of color formulations and the associated savings.
Voith's innovative CleanLine traversing cleaning systems for fabrics provide additional benefits for customers compared to established cleaning methods.
With CleanLine, Voith has developed its systems to improve paper quality by thorough cleaning of the fabrics. CleanLine systems are available for all sections of the paper machine either as new installations or as upgrades of existing Voith equipment to remove more contamination from the surface and structure of fabrics. The CleanLine systems work in combination with other Voith products to improve the productivity, runnability, safety and quality of the paper making process.
Maintain Fabric Performance
Clean fabrics are essential for the removal of moisture from the paper web and for achieving the required properties of the finished paper. Voith CleanLine Systems are effective in maintaining the performance of the fabrics and are a cost effective solution to reduce the effects of contamination.
CleanLine Excell – Forming: by cleaning in two directions with a close concentration of fine water jets the forming fabric is much cleaner. Uniform performance of the fabric is achieved because Excell can more easily remove different levels of contamination across the fabric width. The system uses only about 10 percent of the water volume compared to an oscillating high pressure shower and runs on key reference machines in Europe, America and Asia.
CleanLine Excell – Press: has a selection of different cleaning heads for additional cleaning of press fabrics and transfer belts to solve specific problems with contamination, cleaning chemicals or profiles.
CleanLine Extract4D – Dryers: has just been introduced for packaging and newsprint paper grades made from recycled fiber. Up to four directions of water jets directly contact and remove more contamination from the fabric. This unique system has resulted in better runnabilitry on both packaging and newsprint machines due to cleaner fabric surfaces and higher permeability retention.
CleanLine Extreme – Coaters: is a new system for cleaning tensioning fabrics, running successfully on more than 20 top and bottom sections. Productivity is improved because the system can automatically switch between on-line and off-line cleaning to keep the fabrics in good condition. Highest quality of the coated paper is achieved by using an extended air-knife and option of a heated air blower to ensure that the fabric surface is dry when it contacts the coated paper.
With Servolution, Voith is offering customized service packages to improve the performance of its customers and help them increase their productivity. The holistic approach, modular design and easy access to components in the CleanLine systems provides efficient servicing and management of spare parts from a single supplier. Voith provides a comprehensive support package to ensure the highest availability and performance of the cleaning equipment.
The quality of raw material for making paper faces many challenges in the coming years. Voith’s process know-how, understanding of fabrics and wide experience of fabric cleaning systems makes CleanLine the complete solution for fabric cleaning.
The installation of a new NipcoFlex shoe press was part of a comprehensive modernization of the Macedonian Paper Mills in Thessaloniki, Greece. With its help, the company was able to improve the quality and quantity of paper production. At the same time, the use of Voith technology reduced the plant's use of resources and therefore improved the company's competitiveness.
- Better board quality and runability a key criterion
- Voith's integrated overall concept impresses board manufacturer
- Detailed advance planning and close collaboration allow smooth rebuild and production start
The installation of a NipcoFlex shoe press was the first step in a comprehensive rebuild of the BM 1 at Macedonian Paper Mills (MEL) in Thessaloniki. This measure allowed the internationally operating manufacturer of board and packaging papers to increase machine production by 15 percent. But this increase is only one of the goals of the upgrade, as Georgios Georgiadis, the manager of the board factory, explains: “With the new press section we were able to improve board quality characteristics, reduce breaks and therefore significantly increase machine availability.” MEL mainly produces paper for packing foodstuffs on its BM1. In this segment, good printability is a major criterion. The investment in the new press section is therefore an important first step towards meeting customer requirements in the long term.
The NipcoFlex technology used on the BM 1 reliably corrects deviations in the CD profile and ensures a uniform thickness across the entire 4.110 millimeter wide paper web. A large Yankee cylinder and a coating system with drying function improve the smoothness of the surface.
One challenge associated with modernizing the plant was the tight time frame. The Voith service team had just three weeks to complete the project. Thanks to good preliminary planning and the smooth collaboration between all participants the BM 1 could be restarted on 23 July 2017. As the team from MEL was not familiar with the shoe press technology, comprehensive training including visits to similar systems was conducted in the run-up to the rebuild.
As well as improved paper quality and increased production, the new press section offers another advantage: The BM 1 now needs much less steam, which reduces the energy consumption of the machine. Despite this saving in resources, the NipcoFlex technology also enables a higher dry content in the paper web.
Several factors prompted MEL to work with Voith on this project. One of the key aspects was that Voith has more than 150 years of experience in building paper machines, is a technology leader in many areas and is renowned for the high reliability of its products. In addition, MEL has already worked with Voith on numerous projects, the results of which have been consistently positive for the board mill team. Ultimately, Voith also convinced the customer with an overall concept that was integrated technically and financially. That this was the right decision was not just confirmed by the smooth start to production.
“The atmosphere between the individual teams was excellent. The close collaboration with the colleagues from Voith Tolosa even resulted in some friendships,” says Georgiadis, adding: “I will certainly recommend collaboration with Voith to colleagues in the paper and board industry.”
The project is part of a comprehensive upgrade by the board mill. For example, MEL is investing in its own biomass power plant, which not only supplies power to the paper machine but is also used for steam generation.
With the launch of the new Voith OnCumulus offering, Voith customers can now benefit from an IIoT platform with specific visualization and analytics functionalities as well as the first industry-proven applications. OnCumulus enables paper producers to leverage data across the enterprise from all equipment within all facilities to optimize reliability, achieve targeted performance and increase savings that impact the bottom line.
OnCumulus.Platform: one central data hub for digitalization
The IIoT platform OnCumulus.Platform serves as the data hub for data from all kinds of sources – for example plants, production lines, machines and devices. Customers benefit from one central platform for their data from which they can launch their digitalization initiatives. The OnCumulus.Platform is based on open-source and highly standardized technologies. It provides fast, reliable and secure access to data from local machines and systems in the cloud as well as fast provisioning for value creation. The platform is scalable, flexible and extensible at any time.
With OnCumulus, Voith offers an IIoT platform that meets the highest privacy, security and compliance industry standards and best practices, such as CSA, NIST and OWASP. Voith cybersecurity experts ensure end-to-end security, so that the full life cycle of data is secure at all times. OnCumulus customers stay in control of their data in every usage scenario and define the data access. Furthermore, Voith supports local control of the data by providing data centers in every region.
OnCumulus.Suite: the first step towards visualization and analytics
Besides the IIoT platform, the OnCumulus.Suite offering already provides the first possibilities to benefit from data intelligence: by prestructuring the available data using visualization and analytical functionalities, customers benefit from the first basic, easy-to-use tools, namely: Information Flow, Monitoring and Alarming Tool, as well as Analysis. Therewith, customers can access their data in near real time and take the first step for optimizing their operating process by using persona-based dashboards.
Industry-specific applications: OnEfficiency and OnCare
In addition to OnCumulus.Suite, Voith is offering further value to its customers by launching the first solutions from the existing product families OnEfficiency and OnCare as cloud-based OnCumulus applications. Examples from the paper production industry already show the efficient and value-adding use of the new IIoT platform OnCumulus.
Applications in the Voith OnEfficiency product family:
• OnEfficiency.Pulp: Achieving the required product quality along with reduced raw material costs can be provided thanks to integrated, real-time insights and continuous guidance along the production process.
• OnEfficiency.Strength: Optimizing fiber utilization and strength agents result in a reduced off-spec production. Furthermore, the paper quality during grade changes is ensured by the reduction of fluctuations and peaks.
• OnEfficiency.DIP: Rebuilding the flotation cell in combination with Papermaking 4.0, Advanced Process Controls and modern sensors, increases yield and reduces operating costs.
• OnEfficiency.Dewatering: Using vacuum in the forming section as an actuator to stabilize the dry line will improve ply bond, increase runnability of the forming section and save energy.
From the Voith OnCare product family:
OnCare.Asset: Implementing tools for maintenance management increases the efficiency of maintenance activities, while at the same time reducing costs and saving resources. The next step is to anticipate and optimize the overall process.
Using the applications on the same cloud-based technical platform, customers benefit from bridging information and data views cross-site and cross-app, and therewith leverage untapped correlation possibilities for more advanced insights and transparency. External information such as raw materials prices, weather data, or connections to webshops or warehouses, can be easily integrated and correlated with existing operational data.
By combining the OnCumulus.Suite with the new cloud-based applications of the proven solutions, paper producers profit not only from the increase in efficiency, productivity and quality of the entire production supply chain, but also gain new additional possibilities.
“Thanks to the enormous developments within information and communication technologies, customers can now take the chance to benefit from technologies that offer faster data exchange, big data analytics and cloud solutions,” says Dr. Roland Münch, CEO Voith Digital Solutions. “OnCumulus enables our customers to intelligently benefit from this digital transformation – with optimized processes, improved use of resources, flexibility and security – so that they improve competitiveness and achieve future viability.”