For the fourth time in a row, Voith Paper has been entrusted with a very complex project by paper and cardboard mill Papier- und Kartonfabrik Varel, Germany. Along with increasing the production capacity and expanding the range of products on the PM 4, the core goals were efficient energy use and environmentally friendly paper production.

The PM 4 was successfully restarted in mid of July after its extensive rebuild. Corrugated media and test liners with a basis weight range of 120 to 220 g/m² are produced. In the future, up to 50% of its capacity should consist of white test liner. The PM 4 is designed for a net cut working width of 5,100 mm and an annual capacity of 300,000 metric tons.

Due to the raw materials that will now be required, the rebuild included a significant expansion of the stock preparation on three lines for which Voith provided the essential machines. Worth mentioning here is a patented system for the white stock preparation line.

The paper mill received new approach flow systems, the headboxes were renewed, and both fourdriniers were extended. A DuoFormer D hybrid former was installed on the back ply, while the top ply received a DuoShake shaker unit. The dryer was completely renewed and a SpeedSizer film press with contact-free web drying was integrated. In addition, the PM 4 received a soft calender and MasterReel rewinder. A new unwinder for larger full reel spools was installed on the winder.

Furthermore, Voith was responsible for the modernization of the paper machine controls and the OnQ ModuleJet profile control system. The complete contact-free drying as well as roll covers, clothing, and doctor blades were included in the scope.

Varel hopes to achieve significant energy savings after the rebuild. Environmental aspects are of critical importance. Varel wants to manufacture environmentally friendly products as resource-saving as possible. A significant reduction in the CO₂ emissions of the entire paper production is the goal.

Together with the PM 5, which was provided by Voith Paper as well and also has a capacity of 300,000 metric tons, Varel can offer the entire range of products processed by the corrugating media industry on a 100% recovered paper basis.