Displaying items by tag: voith

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.

Voith has just introduced CleanLine Extract4D in the drying section for packaging and newsprint paper grades made from recycled fiber.

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.

Leading Technology
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.

Servolution
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.

Voith NipcoFlex shoe press at Macedonian Paper Mills BM1

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 brings value-adding industry-proven applications to the cloud, benefiting from a unique, modular offering of an IIoT platform.

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.”

In Schwedt, Voith has converted the LEIPA Group’s PM 5 from a newsprint to a packaging paper machine. On 19 April 2018, the acceptance and handover of the machine of the Schwedt PM 5 project was signed early at LEIPA Georg Leinfelder GmbH, with effect on 13 April. As a result, the Voith team on site managed to bring the entire machine, consisting of a BlueLine OCC stock preparation line, DIP stock preparation line and XcelLine paper machine up to handover quality just 19 days after ‘stock on wire’.

Perfectly matched components and an extensive automation system including OnQ quality control system make the machine a new benchmark in the industry. LEIPA can produce approximately 450,000 metric tons of white top testliner (WTTL) on the machine and is therefore the market leader in this segment. After taking over the UPM mill in Schwedt, the new owner, the LEIPA Group, decided to extensively rebuild the existing PM 11. Under the management of Voith, the conversion of the newsprint paper machine to a machine for the production of white top testliner (WTTL) began in October 2017. LEIPA invested over 160 million euros in the plant. Now known as PM 5, the machine is a new point of reference for packaging paper. Just a few machines worldwide surpass its 9,200-millimeter wire width. It also takes the top spot with its production speed of 1,200 meters per minute. LEIPA plans to produce 1,180 to 1,400 metric tons of white top testliner per day with the best surface properties and basis weights of 100 to 140 grams per square meter. LEIPA wants to manufacture a total of 450,000 metric tons of paper every year and thus expand its market position further.

LEIPA PM 5 project team, from left to right: Martin Kaltenegger, Project Manager LEIPA PM 5, Christian Merz, Chief Commissioning Engineer Voith Paper, Falk Friedrich, Plant Manager LEIPA Schwedt Nord

Optimized for high speeds
To ensure the PM 5 can meet the desired output and quality requirements, Voith modified almost every component of the existing machine. A new hybrid former with two headboxes DuoFormer D and TopFormer F replaced the previous former, for example. Voith also developed a comprehensive solution for the transition to the press section and for the press, with a DuoCentri NipcoFlex shoe press in the center. These two components were designed to meet the requirements in high speed machines and enable outstanding product quality. Robust SolarPress roll covers assist in achieving this. The covers do not require any water cooling and help LEIPA to conserve resources. The SpeedSizer AT is also optimized for the uniform and faultless application of starch at high speeds.

During the rebuild, Voith separated the existing dryer section into a pre-dryer and after-dryer section. In the process, the pre-dryer section received a completely new TopDuoRun dryer group, while existing components were used for the after-dryer section. Thanks to a new MasterReel reel and the rebuild of the two existing DuoRollers, reel diameters of up to 3.5 meters can now be produced on the PM 5. The existing machine hall ventilation system was also expanded and integrated into the new process and quality control system.

15,000 recorded signals ensure optimum paper quality
Some of the existing motors were also used after the conversion. However, the Voith team integrated more than 333 new motors of different sizes into the PM 5, the most powerful of which has a capacity of 1.5 megawatts. Most of the motors are integrated into the automation concept developed by Voith. The system records more than 15,000 signals, monitors all the production steps from stock preparation to the reel, reports even the slightest deviations and levels out any fluctuations within a fraction of a second where needed. 29 state-of-the-art computer processors take care of processing the information. “The continuous data stream forms an important basis for us to maintain a consistently high paper quality at all times”, says Falk Friedrich, Plant Manager of LEIPA Schwedt Nord.

Increased efficiency for paper treatment
While the rebuild was taking place, a new machine for the efficient treatment of up to 1,400 metrics tons of fiber from recovered paper per day was also built. With a length of 50 meters, a diameter of 4.5 meters and a total weight of about 200 metric tons, the IntensaDrum pulping drum is the largest Voith has supplied to date. Much of the existing deinking system (DIP) was retained. Voith only had to modify it to cope with the characteristics of packaging papers. Among other measures, the technology group installed energy-saving components for bleach and flotation, which, along with the new cleaning system, reduce fiber losses.

“The engineers from Voith view the system from the apron conveyor to the winder, including measuring, automation and ventilation technology as a whole, and therefore develop perfectly compatible solutions”, emphasized Martin Kaltenegger, Project Manager for LEIPA PM 5.

Voith clothing for optimum performance
In addition, the order volume included start-up and a number of training sessions in which the LEIPA team became familiar with the intricacies of the PM 5. Voith will remain closely involved in the processes of the PM 5 after start-up too. In the next few years, the single-source supplier will deliver the clothing and doctor blades for the machine and thus ensure the optimum performance of the PM 5. The optimization of the machine within the first eight weeks after start-up is also part of the project – with an option to extend it for longer. “The entire project, from the shutdown of the PM 11 to the installation of the new components and start-up of the new PM 5 has gone very well. With their professionalism and dedication, the two project teams have ensured the success of the project”, says Robert Osswald, Project Manager Voith Paper.

About the company
Voith Paper is a Group Division of Voith and the leading partner and pioneer in the paper industry. Through constant innovations, Voith Paper is optimizing the paper manufacturing process, focusing on developing resource-conserving products to reduce the use of energy, water and fibers. Furthermore, Voith Paper offers a broad service portfolio for all sections of the paper manufacturing process.

Voith is a global technology group. With its wide range of plants, products, services and digital applications, Voith sets standards in the markets for energy, oil and 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.

High dewatering efficiency and long service lives have made press fabrics from the Voith Infinity series best-sellers for packaging papers, board and graphic paper grades. The technology group has now extended its product range. Infinity FineLine offers an ideal solution for sensitive applications like tissue or specialty papers. The modular structure of the press fabrics allows easy adaption to any requirement.

• Minimized seam loops at consistently good closability
• Highly durable when combined with twisted yarn
• Energy efficient through low grammage

With its new FineLine module, Voith is further expanding its successful range of Infinity fabrics. For the new products, a particularly fine loop structure was developed and the seam zone was further improved. FineLine is mainly used in the tissue and specialty paper segment. The new press felt is available as endless and seam product. Infinity FineLine debuts with remarkably minimized seam loops that reduce marking potential even in the finest papers. As with all Infinity products, the seam loops in FineLine also have an identical loop length, roundness and spacing. This makes the closure particularly simple and enables machine downtimes to be reduced by up to 25 percent.

For Infinity FineLine, an especially fine loop structure was developed and the seam zone was further improved. This is why these press fabrics are used above all in the tissue and specialty paper segment.

A combination of Infinity FineLine and twisted yarns has proven particularly advantageous in sensitive applications. The twisted yarns ensure better batt fiber anchorage. As a result, the paper producer benefits from consistent performance over the entire service life. At the same time, Infinity FineLine is specifically energy efficient through its low grammage.

Cohesive range for all requirements
Alongside FineLine, the Infinity series also includes the ToughLine range of fabrics which Voith designed specifically for extreme environments. These conditions occur, for example, when manufacturing board and packaging papers, where the felts are continuously exposed to heat or abrasive materials. The use of Infinity press fabrics for the production of graphic papers is also constantly increasing. “Our Infinity series offers the best press felts portfolio for all paper machine requirements”, says Anne Klaschka, Global Product Manager Press Fabrics at Voith. The modular structure of the fabrics means that they can be tailored optimally to customer requirements.

The Infinity series is part of the PressMax portfolio of the Voith AdvancedProducts range. It allows paper makers a combination of perfectly coordinated components to improve the performance of their paper machines.

About the company
Voith Paper is a Group Division of Voith and the leading partner and pioneer in the paper industry. Through constant innovations, Voith Paper is optimizing the paper manufacturing process, focusing on developing resource-conserving products to reduce the use of energy, water and fibers. Furthermore, Voith Paper offers a broad service portfolio for all sections of the paper manufacturing process.

Voith is a global technology group. With its wide range of plants, products, services and digital applications, Voith sets standards in the markets for energy, oil and 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.

With BrokeGo, Voith has developed a reliable fabric for broke conveyors which quickly and safely removes broke following a web break. The strong and highly wear-resistant belt transports the broke directly to a pulper for further processing.

The ribbed surface of the Voith BrokeGo stops the paper slipping from the belt. The underside is made from wear-resistant material, which results in a longer service life.

Web breaks cannot always be avoided. Generally, the broke paper drops into  an area underneath the machine. To remove this broke efficiently and safely, Voith has developed BrokeGo, which is suitable for all paper grades. The ribbed upper surface stops the paper slipping from the belt. The underside is made from wear-resistant material, which results in a longer service life.

BrokeGo needs to have very different properties from the dryer fabrics that are often used as conveyor belts in the broke conveyor. BrokeGo was specially developed to meet the specific requirements of paper transport after web breaks in particular.

About Voith Paper
Voith Paper is a Group Division of Voith and the leading partner and pioneer in the paper industry. Through constant innovations, Voith Paper is optimizing the paper manufacturing process, focusing on developing resource-conserving products to reduce the use of energy, water and fibers. Furthermore, Voith Paper offers a broad service portfolio for all sections of the paper manufacturing process.

About Voith
Voith is a global technology group. With its broad portfolio of systems, products, services and digital applications, Voith sets standards in the markets of energy, oil & gas, paper, raw materials and transport & automotive. Founded in 1867, Voith today has more than 19,000 employees, sales of €4.2 billion and locations in over 60 countries worldwide and is thus one of the largest family-owned companies in Europe.

Voith Paper, world leader in innovation for the paper industry, completed the successful start-up of the TM 6 XcelLine machine at SEPAC, a company headquartered in the Brazilian state of Paraná that is among the country’s five largest manufacturers of tissue paper for sanitary purpose. Installed in the company’s Mallet plant in Paraná, the TM 6 machine went into service at the end of 2017 and produced paper within the necessary quality specifications from the very first day. The machine is capable of producing nearly 110 metric tons of paper per day and has a design speed of 2,000 meters per minute.

Voith’s scope of supply covered the entire tissue machine, which was fitted with a MasterJet Pro T headbox, a CrescentFormer, a NipcoFlex T shoe press, an EvoDry Y steel Yankee cylinder, a high-efficiency EcoHood T hood and a MasterReel winder. The project also included the ancillary systems, automation systems, as well as installation supervision, commissioning and complete start-up assistance.

The project’s main features are the NipcoFlex T shoe press and its 4.8 meter steel Yankee cylinder, which besides ensuring greater speed and quality, enables SEPAC’s machine to consume up to 20 percent less thermal energy.

The project is part of the growth strategy pursued by SEPAC, a company focused on manufacturing tissue paper from virgin cellulose fibers, and will increase its annual production capacity to approximately 180,000 tons, making it one of the country’s largest tissue manufacturers. SEPAC’s growth strategy began in 2007, with the purchase of its TM 3 from Voith. Over the last ten years, Voith has supplied four tissue machines to SEPAC – a clear demonstration of the successful partnership built on trust and respect that the companies have developed over the period.

About SEPAC
Sepac is one of Latin America’s largest tissue paper producers, with 40 years of experience in the domestic and international markets. Headquartered in the state of Paraná, the company is a market leader in the segment of tissue paper for sanitary purposes in Brazil’s South Region. Its state-of-the-art manufacturing facilities in Mallet (located in the Brazilian state of Paraná) and its successful distribution network reinforce the company’s significant growth potential. Sepac’s towels, napkins and toilet papers are marketed in all regions of Brazil and the Mercosur countries under the Duetto, Paloma, Maxim and Stylus brands.

In 2017, Sepac also joined the personal care segment with the launch of its BabyBoo disposable diapers brand. The operation is initially focused on the special and value segments with the BabyBoo “Fases” and BabyBoo “Dia a Dia” lines, which are distinguished by their attributes of absorption, comfort and anatomical shape.

About Voith Paper
Voith Paper is a Group Division of Voith and the leading partner and pioneer in the paper industry. Through constant innovations, Voith Paper is optimizing the paper manufacturing process, focusing on developing resource-conserving products to reduce the use of energy, water and fibers. Furthermore, Voith Paper offers a broad service portfolio for all sections of the paper manufacturing process.

About Voith
Voith is a global technology group. With its broad portfolio of systems, products, services and digital applications, Voith sets standards in the markets of energy, oil & gas, paper, raw materials and transport & automotive. Founded in 1867, Voith today has more than 19,000 employees, sales of €4.2 billion and locations in over 60 countries worldwide and is thus one of the largest family-owned companies in Europe.

Grupo Gondi has entered into a contract with Voith to supply a new paper machine with an annual production capacity of 400,000 metric tons. The new paper machine will be located in a facility in Monterrey in Northern Mexico. Voith will supply the complete BlueLine stock preparation and XcelLine paper machine from wet end process to winder, which should minimize the number of interfaces for the customer and maximize the operating efficiency of the project.

From early 2020, the new state-of-the-art PM 7 will operate at the new Papel y Empaques Monterrey (PEM) plant. The machine will have a working width of 6,660 mm at the reel and a design speed of 1,200 m/min to produce testliner and corrugated medium with basis weights in the range of 90 to 250 g/m2.

"With the new paper machine, Grupo Gondi will strengthen its position in the Mexican market for high-performance light weight recycled containerboard. It will also enhance our integration levels since our converting capacity has risen in recent years as we have expanded converting plants and grown through acquisitions. Voith will supply an extended scope of services, including the stock preparation, the paper machine, supporting sub systems and automation. Voith’s ability to deliver an advanced, full-line, state-of-the-art system was very important to us and we continue to work closely with our partners at WestRock in connection with project planning and execution," states Eduardo Posada, CEO at Grupo Gondi.

The XcelLine paper machine offers a range of special technical features that both improve the quality of the finished paper and reduce energy consumption. The scope of supply also includes a Tandem NipcoFlex Press, a TopFormer F, and an EcoCal calender. Moreover, the PM 7 will be equipped with a VariFlex NG winder with an operational speed of 2,500 m/min, with MCS, DCS and QCS completing Voith’s scope of delivery. Voith will supply the project with an extended scope, including detailed engineering for process, automation and electrical engineering.

In addition to the paper machine and the BlueLine stock preparation system, MERI, a Voith company, will supply the major sub-systems – material handling, internal water treatment, sludge handling, and reject handling. These systems are designed to lower operating costs while maintaining a clean and safe working environment.

About Grupo Gondi
Grupo Gondi is a leading paper packaging company in Mexico, strongly committed to its consumers, collaborators, investors, the environment and Mexico – where, over the past 65 years it has positioned itself as one of the major players in the paper and packaging industry. WestRock Company, a multinational provider of paper and packaging solutions for consumer and corrugated packaging markets, is a minority shareholder of Grupo Gondi.

Grupo Gondi is composed of 14 companies and a labor force of more than 7,500 employees. Thanks to our multi-plant approach the company offers integral packing and packaging solutions, specializing in the production of recycled paper, corrugated cardboard boxes, pre-printed corrugated boxes and solid fiber containers, folding containers, micro-corrugated and digital cardboard boxes as well as services that support the manufacture of these products.

Grupo Gondi relies on certified processes, international standards which allow the company to offer high-quality products and services on the market, based on a vertical integration that comprises the manufacture of paper from 100% recycled fibers as well as the creation of consumables and tools that contribute to the manufacture of the final product. In addition, Grupo Gondi exports packaging products indirectly to over 189 countries, having presence in the five continents.

About Voith
Voith Paper is a Group Division of Voith and the leading partner and pioneer in the paper industry. Through constant innovations, Voith Paper is optimizing the paper manufacturing process, focusing on developing resource-conserving products to reduce the use of energy, water and fibers. Furthermore, Voith Paper offers a broad service portfolio for all sections of the paper manufacturing 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.

A narrow time window, a size press operating at its maximum speed and the need for greater machine efficiency were the various challenges faced by the Voith team as it tackled the upgrade of the PM 6 at Smurfit Kappa. Thanks to excellent planning beforehand, the machine was restarted without problems one day ahead of schedule.

• SpeedSizer AT extends the operating window for packaging paper production
• Reconditioning of existing Nipco deflection compensation rolls
• Smooth startup with new components

“The startup of the new SpeedSizer has shown how expertise and dedication bring about an excellent outcome. The project simply flew by,” says Jochem Meier, Manager Operations at Smurfit Kappa in Zülpich.

Smurfit Kappa wanted to achieve a higher production speed through its modernization of the PM 6 at the Zülpich mill. The company is one of the leading manufacturers of packaging in Europe. At its facility in Zülpich it produces premium quality testliner and recycled fluting in basis weights of 100 to 150 grams per square meter from 100 percent recovered paper.

Martin Lehrner Voith Paper Global Product Manager at the SpeedSizer AT on the PM 6 in Zülpich

Because the machine was only supposed to be shut down for a week for the conversion, detailed advance planning was absolutely essential for the success of the project. The excellent longstanding relationship between Voith and the customer facilitated this planning. For example, Voith’s service team had previously carried out maintenance on the PM 6 on an ongoing basis. However, the narrow time frame was just one of the challenges.

A key aspect of the project was the puddle-type size press. Equipped with a deflection compensation roll, it allowed an optimum CD profile of the nip load (linear contact pressure) and for a long time had guaranteed the high quality of the paper. But for technical reasons, the size press limited the production speed of the PM 6 to 1,150 meters per minute. Even though the size press was one of, or perhaps even the fastest in the world, it prevented the machine from being ramped up to the 1,225 meters per minute desired by the customer.

This is why Voith recommended installing a customized SpeedSizer AT with the existing Nipco deflection compensating roll system. This application system enables excellent coating and size profiles even at high speeds. Its use increases the operating window of the PM 6 and offers Smurfit Kappa more production flexibility. The SpeedSizer ensures an increase in the solids content of up to 17 percent and reduces the moisture ingress into the paper web. This results in a higher dry content downstream of the SpeedSizer AT, which helps substantially reduce drying energy and achieves much improved paper web running properties.

Voith SpeedSizer AT PM 6 Smurfit Kappa ZülpichVoith used a Nipco roll that was already being used in the old puddle-type size press as a deflection compensation roll. Following comprehensive reconditioning, they now also ensure optimum CD profiles and consequently high paper quality in the new machine as well. The re-use of the previous rolls reduced the costs of the upgrade.

The new SpeedSizer AT plays a major role in reducing the energy consumption of the PM 6. Immediately, a 15 percent reduction in steam consumption could be achieved. The specific energy figures are of course also improved as a result of the higher production rate. A good startup is extremely helpful, because the completely closed water circuit at SK Zülpich Papier has to be evaporated again after a week of shutdown.

The use of the new UniFilm T applicator roll cover, which is very wear-resistant, ensures good metering rod service life and more efficient production. In the PM 6 they run for more than 400 hours, well above the average for comparable machines.

About Voith Paper
Voith Paper is a Group Division of Voith and the leading partner and pioneer in the paper industry. Through constant innovations, Voith Paper is optimizing the paper manufacturing process, focusing on developing resource-conserving products to reduce the use of energy, water and fibers. Furthermore, Voith Paper offers a broad service portfolio for all sections of the paper manufacturing process.

About Voith
Voith is a global technology group. With its broad portfolio of systems, products, services and digital applications, Voith sets standards in the markets of energy, oil & gas, paper, raw materials and transport & automotive. Founded in 1867, Voith today has more than 19,000 employees, sales of €4.2 billion and locations in over 60 countries worldwide and is thus one of the largest family-owned companies in Europe

The Infinity ToughLine press fabric maintains its consistently high void volume even when exposed to high line load and substantial degree of wear. A constant water flow guarantees consistent performance over the entire life of the fabric.

• For use in particularly challenging environments
• Simple and fast seam closure
• Successfully tested at Chinese paper mill

ToughLine – as the name suggests, is the new range of press fabrics from the Voith Infinity family specifically designed for use in extreme environments. These conditions occur, for example, when manufacturing pulp, board and packaging papers, where the fabrics are continually exposed to heat or abrasive materials. Nevertheless, they have to reliably drain the paper webs and perform consistently in the process. Paper quality deteriorates as soon as fabric structures become compacted during operation.

Voith offers Infinity ToughLine with and without seam. The modular structure of the fabric means that it can be tailored precisely to customer requirements.

Voith uses the latest weaving technologies which produce a genuinely laminated structure to avoid this compaction in its Infinity ToughLine press fabrics. This enables the fabric to remain very stable in both MD and CD over its entire life and to constantly retain its high void volume. Good compressibility and excellent resiliency also give the press fabrics a high dewatering capacity. The stable high void volume of the fabric and its drainage capacity ensure minimal dirt deposits, creating the basis for a consistently high paper quality. Voith offers Infinity ToughLine with and without a seam. The modular structure of the fabric allows it to be tailored precisely to customer requirements.

Successfully tested
A Chinese paper manufacturer was one of the first of Voith's customers to test Infinity ToughLine with a seam. The company’s conclusion is that the time for changing the fabric is cut in half. Previously, the paper producer had used conventional endless fabrics. However, these are very time-consuming to change and also present safety risks. If a seamed fabric is used instead of an endless fabric, there is no need to open the whole machine. The new fabric can be easily joined with the old fabric and pulled into the machine where it can be closed. All Infinity ToughLine seam loops are of identical loop length, shape and spacing, joining the seam is quick and easy.

A Chinese paper manufacturer was one of the first of Voith's customers to test Infinity ToughLine with seam. As a consecence the time for changing the fabric was cut by 50 percent.

Even though the use of seamed fabrics offers great savings in time and costs, many paper manufacturers continue to rely on endless fabrics. They are concerned that the seam will leave marks on the paper and therefore cause additional waste. Meanwhile, market experience with Infinity ToughLine shows that the new press fabric does not leave any marks on the paper web over their entire life and ensures a consistently high paper quality. Convinced of the results, the Chinese paper producer has converted its machine entirely to fabrics with seam in the meantime.

Infinity ToughLine is available with PeakElement the elastomer component available for all Voith press felt designs. Infinity is part of the PressMax range of Voith AdvancedPRODUCTS. Alongside individual products, PressMax offers papermakers the opportunity to enhance the performance of their paper machine through the ideal combination of perfectly matched products.

About Voith Paper
Voith Paper is a Group Division of Voith and the leading partner and pioneer in the paper industry. Through constant innovations, Voith Paper is optimizing the paper manufacturing process, focusing on developing resource-conserving products to reduce the use of energy, water and fibers. Furthermore, Voith Paper offers a broad service portfolio for all sections of the paper manufacturing process.

About Voith
Voith is a global technology group. With its broad portfolio of systems, products, services and digital applications, Voith sets standards in the markets of energy, oil & gas, paper, raw materials and transport & automotive. Founded in 1867, Voith today has more than 19,000 employees, sales of €4.2 billion and locations in over 60 countries worldwide and is thus one of the largest family-owned companies in Europe.