Pulp-Paperworld.com / European News
2018 07 04 151129
Evolution, innovation and ongoing research.

These are the main elements on which the clear vision of A.Celli Paper is based.

During the third edition of iT’s Tissue (Lucca, 25-29 June 2018), A.Celli Paper welcomed visitors to discover the great path it has chosen, inviting them to see for themselves the 11 technology stations representing the same number of system solutions for complete turnkey plants.

The FROM TISSUE TO TISSUE tour was a unique experience, offering a special opportunity to view a complete Tissue production line.

It was an occasion to present the new generation of the iDEAL® Tissue Machine, the E-WIND® winders and the innovative R-WAY® Roll Handling & Packaging system.

But this was just the beginning, because the journey planned for the visitor also included a look at Research and Development and the new solutions in the context of the Yankee Dryer, with our FORGED YD®; the revolutionary iREEL® data traceability and analysis system; and the latest R-WAY® reel management system with automated guided vehicles (AGVs): all in the name of efficiency, safety and automation.

The visitors were impressed by this direct contact with the world of A.Celli equipment solutions, which is all about the best in production efficiency, reduced consumption and costs, and excellence in terms of both quality and technology.

We would like to thank all those who came, and hope to see you again next time.

A.Celli is on a roll!

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Mondi has recently enhanced the portfolio of its key paper brands Color Copy and PERGRAPHICA® in new digital formats to offer bulk-packed paper options saving its professional printing customers time and money while increasing speed and efficiency.

The market leader for digital colour printing Color Copy is now offered with new digital formats as SRA3, SRA3+, A3+ and 33 x 48.3 cm, all of them available in long grain (LG) and short grain (SG). The SG format is the standard format for A4 brochure printing or book-on-demand printing and is now available bulk-packed, with reams on the pallet with or without a box enabling high-volume, long-run print jobs to run more smoothly. The offer specifically targets professional printing businesses looking for best possible printing results with satisfaction guaranteed, and getting the benefits of the finishing options.

Mondi’s premium design paper PERGRAPHICA® has also extended its offer to the creative and premium print industries, and is now available in a bulk-packed and reamed on pallet SRA3 format in both long grain and short grain options. The recent SRA3 update allows designers to digitally print and review their work on PERGRAPHICA® paper thus testing it, before actually going to (offset) print. In line with the brand’s promise and thanks to the product’s versatility, this addition supports designers to achieve outstanding printing quality turning their vision into reality.

“Customer satisfaction and flexibility are key drivers in our strategic planning,” says Mondi Marketing and Sales Director Johannes Klumpp. “For designers and printing professionals, grain direction in paper is critical, as it influences the paper’s creasing and folding behaviour. Our new folio line offers perfect cutting quality and accuracy direct from the mill, which together with our fully automated pallet stacking offers a clear competitive advantage for our flagship brands Color Copy and PERGRAPHICA®.”

About Color Copy

Color Copy is the leading brand for digital colour printing and is CO2 neutral. It is specifically designed to meet the needs of digital printing and guarantees true-to-life, brilliant colour copies and perfect print results every time. Color Copy has an elegant and smooth feel and its soft white hue gives accurate colour reproduction that emphasises your image. It also has an exceptional environmental profile, being CO2 neutral in addition to having FSC®, EU Ecolabel and ISO 9706, ISO 14001 and ISO 18001 certifications. Color Copy is part of Mondi’s Green Range of sustainably produced products.

www.colorcopy.com

www.facebook.com/ColorCopyPaper/

About PERGRAPHICA®

PERGRAPHICA® is Mondi’s premium design paper range that covers the needs of the creative and premium print industries. PERGRAPHICA® fulfils the most demanding requirements for sophisticated and elegant printed documents while meeting top sustainability standards. The portfolio provides excellent printability and it is available in two textures (Rough and Smooth), three shades (High White, Classic and Natural) and six grammages between 90 and 300 g/m2. Customers in many European countries can purchase PERGRAPHICA® through local distribution companies.

http://pergraphica.mondigroup.com

https://www.instagram.com/pergraphica/                                    

About Mondi

Mondi is a global leader in packaging and paper, delighting its customers and consumers with innovative and sustainable packaging and paper solutions. Mondi is fully integrated across the packaging and paper value chain – from managing forests and producing pulp, paper and plastic films, to developing and manufacturing effective industrial and consumer packaging solutions. Sustainability is embedded in everything Mondi does. In 2017, Mondi had revenues of €7.10 billion and underlying EBITDA of €1.44 billion.

Mondi has a dual listed company structure, with a primary listing on the JSE Limited for Mondi Limited under the ticker MND, and a premium listing on the London Stock Exchange for Mondi plc, under the ticker MNDI. Mondi is a FTSE 100 constituent, and has been included in the FTSE4Good Index Series since 2008 and the FTSE/JSE Responsible Investment Index Series since 2007.

www.mondigroup.com

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.

SmoothRun helps achieve higher operating speeds and improved winding results.SmoothRun helps achieve higher operating speeds and improved winding results.

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.

The new functional coating of TerraSpeed Supreme ensures very stable roughness values and outstanding sheet release.The new functional coating of TerraSpeed Supreme ensures very stable roughness values and outstanding sheet release.

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.”

The SkyTerra S blade with negative facet was specially developed for use with TerraSpeed Supreme.The SkyTerra S blade with negative facet was specially developed for use with TerraSpeed Supreme.

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.

2018 07 04 090659Magnus 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.

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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.

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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.

Valmet Pulp Analyzer (Valmet MAP)Valmet Pulp Analyzer (Valmet MAP)

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.

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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.

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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.

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