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.
SCA has employed Magnus Kangas as new Mill Manager of Ortviken paper mill in Sundsvall. He will take on his new postion as of January 1, 2019.
Magnus Kangas comes to Ortviken from a position as manager of BillerudKorsnäs’ paper mill in Gävle. He has held a number of leading positions in the paper industry and the energy sector.
Magnus Kangas is succeeding Kristina Enander, new President of SCA’s business area Pulp.
“With Magnus Kangas, the Ortviken paper mill will get a very experienced leader with broad experience from Sweden and abroad”, says Mats Nordlander, President of SCAs business area Paper .
Ortviken paper mill in Sundsvall produces coated and uncoated publication paper, has a capacity of 775,000 tonnes per annum and 625 employees.
Millions of fans of Chip and Joanna Gaines, of Magnolia Homes and HGTV’s Fixer Upper fame, are getting a taste of quality from Domtar’s Rothschild Mill this year. That’s because Joanna Gaines’ new cookbook, “Magnolia Table: A Collection of Recipes for Gathering,” was printed on 80-lb. Lynx® paper made at Rothschild Mill.
The book, published by HarperCollins, includes personal stories and homestyle recipes of family favorites and classic comfort food from the couple’s new restaurant in Waco, Texas. It has received glowing reviews from lovers of all the Magnolia Homes brand and was a New York Times No. 1 bestseller.
Our Rothschild Mill colleagues also received high marks from the publisher; Domtar has worked with HarperCollins for more than 20 years. It’s rewarding to know that our customers and partners value our high-quality Lynx paper and excellent customer service.
When the book’s paper run began, Rothschild Mill Manager Dave Faucett and key team members made the 10-hour drive from Rothschild to HarperCollins’ printer in Willard, Ohio, to discuss the quality of the Lynx paper rolls and the project’s specifications.
While there, the group met Tracey Menzies, HarperCollins’ vice president of creative operations and production, who was at the facility to inspect print quality. They had an opportunity to talk about Domtar’s history, values, capabilities and commitment to sustainability. Faucett also emphasized Domtar’s excellent customer service and attention to product quality.
Menzies was impressed, both with Lynx paper and with what she learned in the conversation. The interaction and the successful project prompted her to write a thank-you note to the mill. She also included several copies of the finished cookbook.
Joanna Gaines’ next book, “Homebody: A Guide to Creating Spaces You Never Want to Leave,” also will be printed on Lynx paper made at Rothschild Mill. It will include advice on designing spaces, ideas for every room in the house and photos from inside the Gaines’ family farmhouse. Publication is set for November 2018.
Two UNTHA XR waste shredders are now in operation for VPK Packaging Group in continental Europe, shredding pulped ropes as part of a closed loop paper production process.
Renowned for manufacturing 900,000 tonnes of paper per year from 100% recycled materials, VPK’s mill in Dendermonde, Belgium and Blue Paper Mill, co-owned with Klingele Papierwerke, in Strasbourg, France, naturally generate a waste by-product including complex pulper ropes.
This multifaceted 1:3 metal and plastic material was previously treated off site by a third party. However, the new shredding investment means that both sites can now process the waste themselves to manufacture an alternative fuel for their own energy generation.
At Dendermonde, untreated pulper rope waste is being fed into an UNTHA XR3000C shredder via a ceiling-mounted claw grab, at a throughput rate of five tonnes per hour. A 50mm screen ensures homogenous particle sizing before the fraction drops onto a horizontal discharge conveyor. The shredded material then passes up an elevated conveyor to an electro-magnetic FE-separator, where metals are extracted for onward sale and recycling. The finished product is an SRF specification fuel that VPK uses in its own on-site Waste to Energy facility.
The SRF travels via a final horizontal conveyor into a bunker with walking floor to directly feed the plant. A level detector senses when the vessel is 70% full and the conveyor auto-reverses so that excess material can instead drop into a storage bay.
The complete solution including control cabinet room, steel support, service platforms, stairways and even the cranage sourcing, was supplied by UNTHA as a turnkey package. The tender stated a system capable of handling 5800 tonnes per annum (only during daytime working hours), but the VPK team is already confident that this target will be surpassed.
Commenting on the project, VPK’s Group Energy & Environment Manager Johan Dhaese said: “We are particularly impressed that we can process this waste material in a single step, as two shredders have traditionally been required for pulper ropes. We knew from a reference visit to another client site in Turkey, that this one-step methodology would be extremely effective, which is why we proceeded with the XR investment for both our Belgian and French sites.
“By bringing this process in-house we’ve benefited from cost savings, reduced the carbon impact of unnecessary waste transport and created an entirely self-sufficient closed loop too.”
UNTHA’s sales manager Daniel Wresnik, who was responsible for the project from the outset added: “Pulper rope shredding is a notoriously difficult, heavy duty operation which requires a robust and reliable machine. No two grabs of material are ever really the same, so the shredder must be capable of dealing with whatever is thrown at it.
“We’ve equipped the XR with two cutting rows and a torque+ gearbox for maximum torque on the shaft, which ensures performance without the need for high speeds. We have remote diagnostic capabilities should we need to advise on rotor speed or ram adjustments, for instance, but early indications suggest that the line’s only operator has this process fully under control.”
The complex nature of the input material was not the only challenge with this project. The footprint of the turnkey package was originally designed to sit outside in the open air. However, further research indicated the benefits of enclosing the line , which resulted in the construction of a 180sqm building to house the system. Adjustments therefore had to be made to the height, angle and lengths of the conveyors, and the shredder even had to be lowered into the building using a 100 tonnes crane before the building’s roof was installed.
UNTHA’s machine delivery in the Blue Paper Mill in France is virtually identical, apart from the fact that it will be handling approximately 4,500 tonnes of material per year.
Offering a concluding point, Johan said: “Recycling can become a costly and complex process for paper manufacturers, especially when handling waste such as pulper ropes. At the same time, we are always striving to minimise the net environmental impact of our operations – whilst reducing costs – so it made a lot of sense to manage the shredding, separation and SRF production ourselves. We’re delighted that we’ve been able to fully close the loop.”
VPK has purchased the two turnkey packages outright with an extended warranty package inclusive of service inspections provided by UNTHA’s Austrian engineers.
Valmet has received an order for a Valmet Pulp Analyzer (Valmet MAP) from UPM in China. The Valmet MAP with freeness module and optional Fiber Image module will be installed with six sampling devices for UPM's PM 2 in Changshu.
"We have been using the previous generation Valmet online freeness analyzer on PM 2 for ten years. With technological upgrading and innovation, we again selected the latest Valmet Pulp Analyzer for its fast and precise online fiber and furnish measurement to improve runnability and productivity," says Mr. Zhou Long, Production Manager for PM 2. Installation and start-up is scheduled for the third quarter of 2018.
The Valmet Pulp Analyzer provides paper, board and tissue makers with fast and precise online updates of key fiber and papermaking furnish properties. It represents the state of the art in online fiber analysis, built on continuous advancements by Valmet for the past thirty years. Rather than waiting for infrequent, time-delayed laboratory tests, fast and decisive control actions can be achieved to manage furnish properties for better paper and improved production.
"Valmet MAP will be the ideal tool at PM 2 for furnish management, screening, blending and improving refining operations while providing energy savings as well," according to Jackson Sui, Senior Automation Sales Manager for Valmet in China.
Information about the customer UPM
UPM is a forest-based bio industry company that provides sustainable and safe solutions to the growing global consumer demand. Products are made of renewable materials and they are recyclable. They offer alternatives to replace non-renewable fossil-based materials.
Toscotec fired up other two AHEAD-2.0L PRODERGY tissue machines at APP’s OKI mill, in South Sumatra, Indonesia.
Following the start-up of two AHEAD-2.0L PRODERGY at Perawang mill earlier this year, these two OKI machines started production in less than 3 months after the start-up of the first of a series of Toscotec’s PRODERGY machine ordered by Asia Pulp & Paper (APP) for its Perawang and OKI mills in Indonesia. In the next few months, other four machines will start up at the same site.
The AHEAD-2.0L PRODERGY is Toscotec’s top of the line tissue machine, featuring 5.6 m width, 2,000 m/min operating speed, a second-generation steel Yankee dryer of 22 feet diameter and steam-heated hoods. Toscotec’s TT SYD-22FT is the biggest steel Yankee dryer ever manufactured in the world for tissue application. Toscotec’s energy saving innovations consolidate OKI mill’s optimized green process: the paper mill is fully integrated with a massive pulp mill of 2.8 million ton/yr estimated output.
Equipped with the most advanced environmental technology presently available, OKI production base is very much green-oriented. The mill will be powered by clean and self-sufficient energy generated from the pulp production process and wood bark gasification. Tissue production guarantees the highest standards in terms of tissue machine’s efficiency and energy consumption reduction, thanks to PRODERGY’s technological advantages.
Toscotec’s Chief Customer Service Officer Valter Di Nardo commented, “The erection, commissioning and start-up of OKI tissue machines was completed in record time. Toscotec’s technical team on site installed the first foundation plate on January 4. After just over one hundred days, we fired up the first AHEAD-2.0L PRODERGY, and after one week, the second start-up followed suit. The mill expressed satisfaction for tissue quality starting from day one”.
Sulzer has once again broken the conventions in the name of efficiency. The new CPE ANSI process pumps are specifically designed to exceed the strictest energy regulations for all industries as well as the requirements of ASME B73.1. With revolutionary hydraulics and high efficiency, they offer low life cycle costs.
The new CPE pumps meet the process requirements in a variety of industrial applications, and are suitable for use with clean or slightly contaminated liquids, viscous liquids of up to 3’000 cSt, and fibrous slurries with a consistency up to 6%.
When engineering the new range of CPE pumps, we at Sulzer considered numerous factors that can potentially influence the total cost of ownership of a process pump. The result is an innovative design that makes it possible for the user to achieve remarkable annual savings.
We improved the reliability of the CPE pump and reduced the risk for unplanned shutdowns by optimizing the shaft sealing. Heavy-duty rigid bearing units ensure a long bearing life and further protection against unexpected shutdowns. Learn more on sulzer.com.
The new pump design brings higher efficiency that translates into lower energy consumption. Coupled with this, the high standardization, easy installation and robust construction also equate to lower maintenance and operating costs.
“We are eager to offer our new CPE pump range to our customers, because it fits a wide range of industrial applications and will reduce operating costs.”
Joe Salah, Sales Manager, Sulzer Pump Solutions Inc.
When people think of paper manufacturing, the first natural resource that comes to mind is probably trees. But water plays an equally important role in our industry. That’s why sustainable water management is one of our top priorities.
The location of our facilities shows how important water is to our manufacturing process. We’ve built our mills near abundant water supplies, such as the shores of rivers, to draw water for our operations. Managing these natural resources is important to us and to the communities in which we live.
Water Use at Domtar
In 2017, our pulp and paper mills used enough water to fill 164,000 Olympic-sized swimming pools. But because of our extensive water recycling loops, we can reuse that water an average of 10 times in the mill before we treat it one final time in our onsite wastewater treatment plants. Of the water we bring into our mills, about 90 percent is returned to its original source. The other 10 percent evaporates or becomes part of our products and byproducts.
The water we do use — 94 percent of which comes from surface-water sources such as lakes and rivers — does a lot of work. It’s used to wash and transport pulp, dilute and prepare process chemicals, generate steam and electricity, carry energy and raw materials throughout the mill, and clean and cool equipment.
Each of our mills has a unique water footprint. Mill age, the kind of equipment we use and the types of pulp and paper products we produce are the primary drivers of how much water we use.
For example, specialty papers, such as medical paper, require more water to produce than everyday copy paper. That’s because specialty papers are generally manufactured using shorter runs with more grade changes. They also have more stringent quality requirements, such as FDA requirements for food packaging, which can limit opportunities to reuse water.
A Focus on Sustainable Water Management
Some of our mills, first built in the late 1800s, did not include water conservation features in their original design. But as we’ve upgraded them and built new mills, we’ve placed special emphasis on sustainable water management.
We’re doing our part to conserve water. Our mills have reduced total water use by 4 percent since 2013. That means we can now avoid using enough water to fill 6,560 Olympic-sized swimming pools each year.
“Water is a local resource best managed with site-specific strategies,” says Paige Goff, Domtar’s vice president of sustainability. By understanding the unique challenges and opportunities where we operate, we can manage water usage in a way that helps us be better stewards of this shared resource, making our business and communities more sustainable.
As in many other parts of nature, sustainable water management and sustainable forestry work hand in hand. Forests play a critical role in protecting and conserving valuable water resources by recharging ground water supplies, buffering and absorbing storm water surges, and cleaning and protecting the lakes and rivers our mills and local communities depend on. We support the protection of the forested landscapes, forest wetlands and watersheds from which we source forest and water resources.
We also recognize that we literally are connected to our neighbors through the rivers and lakes that supply our water. As we continue to innovate, we are also working to improve water quality and water management so that we can serve as better stewards of these shared resources. Learn more by reading our 2017 Sustainability Report.
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.