With the new EdgeSaver edge trim concept, Voith is effectively improving its range of products for stabilizing the web edge in the headbox area. The innovative system trims the web edge in the stock jet exiting the headbox. As a result, paper manufacturers not only save valuable raw materials like virgin fibers but also reduce the energy consumption for paper production.

• EdgeSaver trims the web edge in the stock jet as it exits the headbox
• Saves valuable virgin fibers and reduces energy requirement
• Web width can already be adjusted to individual customer requirements in the wet end

In conventional systems, the edge cut on multi-ply machines is only done after couching, so that the mixed trim residues can only be returned to the lower quality stock cycle. By contrast, the innovative design of the EdgeSaver blade offers a simple and energy-efficient solution for adjusting the web edge directly in the headbox jet. Fibers that exceed the required paper web width are not lost in the couch pit, as they are discharged before the suspension reaches the wire. The discharged stock suspension can thus be returned directly to the primary fiber stock cycle in a single-sort process. In addition, the web width can be adjusted to specific customer requirements in the wet end, which offers crucial advantages, above all when producing various paper grades with different run-out widths. As a result, EdgeSaver helps to significantly reduce raw material costs and thus ensures a smaller carbon footprint.

“By using the Voith EdgeSaver we consume less energy and therefore reduce our carbon footprint, because the product allows high-quality fibers to be retained,” says Oliver Kern, Plant Manager at Papier- und Kartonfabrik Varel. “This means, we not only produce more sustainably, but also more cost-efficiently.”

The EdgeSaver also offers an impressive improvement in paper quality. Thanks to its specially manufactured side shield with a patented, adjustable S-shape, edge waves are minimized. This improves edge stability and also facilitates the successful threading of the web into the press section. The Teflon seal on the underside of the side shield provides an optimal seal to the wire. For the first time, the seal can be adjusted with the machine running.

The EdgeSaver can be mounted to the standard headboxes of all manufacturers. It can be easily installed on both sides of the web in just a few hours during a shutdown. Changing the forming fabric is also not a problem, as the ingenious swivel device enables it to be replaced easily without having to restore the optimized settings on the EdgeSaver afterwards.

“The EdgeSaver enables us to variably adjust the paper web width without major rebuild measures. Even with changing production parameters, we are able to produce without restrictions, thus reducing breaks and production losses due to defects in the edge area,” says Andreas Jaeger, Plant Manager at MM Neuss GmbH.

About the Voith Group
The Voith Group is a global technology company. With its broad portfolio of systems, products, services and digital applications, Voith sets standards in the markets of energy, paper, raw materials and transport & automotive. Founded in 1867, the company today has around 20,000 employees, sales of € 4.3 billion and locations in over 60 countries worldwide and is thus one of the larger family-owned companies in Europe

The Group Division Voith Paper is part of the Voith Group. As the full-line supplier to the paper industry, it provides the largest range of technologies, services, and products on the market, and offers paper manufacturers integrated solutions from a single source. The company’s continuous stream of innovations facilitates resource-conserving production and helps customers minimize their carbon footprint. With its comprehensive automation products and leading digitalization solutions from the Papermaking 4.0 portfolio, Voith offers its customers state-of-the-art digital technologies to improve plant availability and efficiency for all sections of the production process.

International technology group ANDRITZ has successfully started up a PrimeFlow AT headbox with dilution control at the Casalino Carta Srl. mill in Rocca Grimalda (Alessandria), Italy.

The aim of the rebuild was to improve the basis weight profiles and formation of the PM1 packaging paper machine, which has a production speed of 305 to 570 m/min and a width of 2.9 m at the pope reel. 

The PrimeFlow AT accelerating tube headbox has uniquely nested trapezoid outlet features – in addition to a rugged design structure – lamellas in the nozzle for turbulence control, and a dilution profiling system with high resolution. This provides excellent jet quality, fiber dispersion and fiber orientation control over a wide range of grades and speeds.

PrimeFlow AT headbox at the ANDRITZ workshop in Graz, Austria © ANDRITZ

Giovanni and Alessandro Casalino, owners of Casalino Carta Srl., say: “We want a high-quality end product so that we number among the top European producers of Ecocraft packaging, corrugated medium and MG-creped paper. This is why we opted for the ANDRITZ equipment. We are convinced that the new headbox will help us to meet our targets.”

Casalino Carta Srl. is one of Italy’s leading packaging and creped paper producers (Ecokraft, parent reels of towel paper, fold and roll towels for hygienic, sanitary and household use), and is putting more and more focus on the production of high-quality packaging grades.

ANDRITZ GROUP
International technology group ANDRITZ offers a broad portfolio of innovative plants, equipment, systems and services for the pulp and paper industry, the hydropower sector, the metals processing and forming industry, pumps, solid/liquid separation in the municipal and industrial sectors, as well as animal feed and biomass pelleting. Plants for power generation, flue gas cleaning, recycling, and the production of nonwovens and panelboard complete the global product and service offering. Innovative products and services in the industrial digitalization sector are offered under the brand name Metris and help customers to make their plants more user-friendly, efficient and profitable. The publicly listed group has around 26,800 employees and more than 280 locations in over 40 countries.

ANDRITZ PULP & PAPER
ANDRITZ Pulp & Paper provides equipment, systems, complete plants and services for the production of all types of pulp, paper, board and tissue. The technologies and services focus on maximum utilization of raw materials, increased production efficiency and sustainability as well as lower overall operating costs. Boilers for power generation, flue gas cleaning systems, plants for the production of nonwovens and panelboard (MDF), as well as recycling and shredding solutions for various waste materials also form a part of this business area. State-of-the-art IIoT technologies as part of Metris digitalization solutions complete the comprehensive product offering.

Solenis, a leading global producer of specialty chemicals, will increase prices by 8 to 15 percent on all polyacrylamide polymers and retention aids across the EMEA region, effective February 1, 2022, or as customer contracts allow.

The price increase is required to offset cost increases in raw materials, packaging, energy and transportation. In addition, Solenis continues to face shutdowns and force majeure declarations from key suppliers.

“Solenis is committed to keeping its customers supplied,” said Naama Lilach, Vice President Commercial Operations, Eurasia, Solenis. “Our recent acquisition of the SCL GmbH business, a leading global producer of primary raw materials for cationic polyacrylamide production, is one of many activities we are currently undertaking that will enable us to secure materials and continue serving our customers.”

About Solenis

Solenis is a leading global producer of specialty chemicals, focused on delivering sustainable solutions for water-intensive industries, including the pulp, packaging paper and board, tissue and towel, oil and gas, petroleum refining, chemical processing, mining, biorefining, power, municipal and pool and spa markets. The company’s product portfolio includes a broad array of water treatment chemistries, process aids and functional additives, as well as state-of-the-art monitoring and control systems. These technologies are used by customers to improve operational efficiencies, enhance product quality, protect plant assets, minimize environmental impact and maintain healthy water. Headquartered in Wilmington, Delaware, the company has 47 manufacturing facilities strategically located around the globe and employs a team of over 6,000 professionals in 120 countries across five continents. Solenis is a 2021 US Best Managed Company.

For additional information about Solenis, please visit www.solenis.com

A.Celli welcomes Daniel Galli, new Plant Director of the A.Celli Paper plant in Tassignano (LU).

The commercial, technological and organizational developments that have characterized the last few years of A.Celli Paper see the addition of a new, fundamental piece for future growth.

Daniel Galli, graduated in chemical engineering from the University of Pisa, has a solid background in the Lean Six Sigma methodology and many years of experience as Operations and Plant Director for numerous companies operating in various industrial sectors.

Daniel Galli, new Plant Director of the A.Celli Paper plant in Tassignano (LU).

Among his professional experiences, we point out the profitable and long-lasting period in force of a well-known multinational in the Oil & Gas sector, which has seen him cover various roles, including that of CEO. Last but not least, the role of Plant Director held for a famous luxury brand, for which he followed the start-up of the first production plant in the province of Florence.

Regarding his new role, Daniel Galli states: “I am honored to cover the role of Plant Director for A.Celli Paper and equally happy to be part of a solid, valid industrial company involved in a highly motivating market. I cannot wait to make the most of the skills and strengths acquired during my career to support my new colleagues and contribute to the development and growth of A.Celli. "

We therefore want to take this opportunity to offer Daniel our best wishes, confident that his professionalism and experience will allow A.Celli Paper to increase its success in the years to come.

International technology group ANDRITZ has received an order from Holmen Iggesund Paperboard Ltd. to supply a state-of-the art primary effluent and sludge treatment line for its mill in Workington, UK.

Start-up is scheduled for the first quarter of 2023.

The mill will completely replace the existing primary effluent treatment plant to improve the efficiency of the system and reduce the level of total suspended solids (TSS) in the outfall.

ANDRITZ will supply a tailormade technological solution, including channel screening, clarifying, automated flocculant and coagulant dosing, and sludge dewatering: 

• ANDRITZ Aqua-Screen channel screens specially designed for handling wastewater streams will ensure effective coarse screening and removal of large contaminants from the influent to the clarifiers.
• Clarifiers will be installed to ensure efficient solid-liquid separation for coastal discharge. The clarifier tanks will be raised off the ground on legs to facilitate operation and maintenance activities.
• State-of-the-art sludge handling line, including proven ANDRITZ gravity tables prior to ANDRITZ sludge screw presses for minimum flocculant consumption, lowest solids load in the filtrate and highest possible sludge dryness.

Holmen Iggesund Paperboard Ltd., UK © Holmen Iggesund

The entire key equipment will be provided with a special surface coating to protect against the harsh coastal environment at the Workington mill.

The scope of supply also comprises field instruments, tanks, agitators, and process pumps as well as installation and service support after commissioning to maintain highest availability of the plant.

As part of the Holmen Group, Holmen Iggesund Paperboard Ltd. is a manufacturer of premium paperboard for various packaging products and focuses strongly on sustainable production processes.

ANDRITZ GROUP
International technology group ANDRITZ offers a broad portfolio of innovative plants, equipment, systems and services for the pulp and paper industry, the hydropower sector, the metals processing and forming industry, pumps, solid/liquid separation in the municipal and industrial sectors, as well as animal feed and biomass pelleting. Plants for power generation, flue gas cleaning, recycling, and the production of nonwovens and panelboard complete the global product and service offering. Innovative products and services in the industrial digitalization sector are offered under the brand name Metris and help customers to make their plants more user-friendly, efficient and profitable. The publicly listed group has around 26,800 employees and more than 280 locations in over 40 countries.

Please see below a product update from ABB who is expanding their portfolio and releasing their new L&W Sample Cutter, a new device for sample preparation that can be used with two of their lab testing devices, the Tearing Tester and Bending Tester. It can also be used with the L&W Autoline Elrepho Module.

The L&W Sample Cutter is a triple shear, manually operated cutting tool for easy and quick preparation of accurate and precise test pieces for use in tearing, bending resistance and folding strength tests. The punch and die are made of sturdy tempered tool steel to ensure precision cutting, essential for reliable testing across a wide range of paper grades and grammages. 

Operation is simple, with the samples needing to be correctly placed in the machine and cross-machine directions aligned with the back stop within the cutter. The ergonomic design and slanting edges of the punch ensure that only slight to moderate force is needed to cut the test pieces. 

The cut test pieces slide towards the operator automatically for quick and safe collection of the test pieces. Furthermore, there is a safety device around the punch to protect the operator from hand or finger injuries.

International technology group ANDRITZ has successfully completed all the performance test runs for the PrimeLineCOMPACT tissue production line delivered on turnkey basis to MG TEC Industry for its mill in Dej, Romania.

Dorin Mocan, CEO of MG TEC Industry, says: “Together with ANDRITZ, we have started up our new tissue production line successfully and are proud of the perfect end-product quality. Based on this success, we have placed a repeat order with the same scope of supply and are looking forward to its installation.”

The energy-efficient PrimeLineCOMPACT tissue machine, with a design speed of 1,900 m/min and a paper width of 2.85 m, produces high-quality tissue grades. It includes an ANDRITZ PrimeFlow headbox with on-the-run jet angle adjustment, a suction pressure roll with drive side exhaust to ensure easy felt and roll change, a 15-ft. PrimeDry Steel Yankee for energy-efficient and safe operation, a PrimeDry Hood G gas-heated Yankee hood, a PrimeDustEXT dust extraction system, and a PrimeMistEXT mist extraction system.

Top tissue quality with ANDRITZ technology at MG TEC Industry, Romania © ANDRITZ

The ANDRITZ scope of supply also comprised:

• A stock preparation line including approach flow system and broke handling: The proven TwinFlo disc refiner technology is used in a separate long-fiber line to achieve optimum development of fiber properties. The approach flow system features the ANDRITZ ShortFlow concept, which allows a minimized number of equipment items and very low storage volume as well as fast grade changes at the tissue machine.
• WeCare Prime forming fabrics and StrataPress press felts for high dryness content and energy savings as well as two Polysoft PU suction pressure roll covers for efficient machine throughput and which contribute towards achieving the targeted running time intervals.
• An ANDRITZ Metris UX Platform for real-time monitoring of energy consumption and efficiency as well as enhanced process tools to optimize production and ensure highest quality control: All service work and optimizations after start-up can be conducted through the Metris Performance Center located at the ANDRITZ headquarters in Graz, Austria.

MG TEC Industry is a newly formed company focusing on innovation and sustainable tissue production.

ANDRITZ GROUP

International technology group ANDRITZ offers a broad portfolio of innovative plants, equipment, systems and services for the pulp and paper industry, the hydropower sector, the metals processing and forming industry, pumps, solid/liquid separation in the municipal and industrial sectors, as well as animal feed and biomass pelleting. Plants for power generation, flue gas cleaning, recycling, and the production of nonwovens and panelboard complete the global product and service offering. Innovative products and services in the industrial digitalization sector are offered under the brand name Metris and help customers to make their plants more user-friendly, efficient and profitable. The publicly listed group has around 26,800 employees and more than 280 locations in over 40 countries.

ANDRITZ PULP & PAPER

ANDRITZ Pulp & Paper provides equipment, systems, complete plants and services for the production of all types of pulp, paper, board and tissue. The technologies and services focus on maximum utilization of raw materials, increased production efficiency and sustainability as well as lower overall operating costs. Boilers for power generation, flue gas cleaning systems, plants for the production of nonwovens and panelboard (MDF), as well as recycling and shredding solutions for various waste materials also form a part of this business area. State-of-the-art IIoT technologies as part of Metris digitalization solutions complete the comprehensive product offering.

Domestic electricity for 45,000 homes for one year. That was the total excess from Södra’s own electricity generation according to new figures from 2021.

With efficiencies, investments and industrial development, Södra is maximising the value of its members’ forest products, as well as the by-products.

New figures show that Södra’s pulp mills at Värö, Mörrum and Mönsterås generated 1,790 GWh in 2021, corresponding to nearly 120 percent of the Group’s annual electricity needs. This means that Södra generated nearly 260 GWh of excess electricity during the year, which was distributed through the local electricity grid and added to the electricity supply in Götaland.

The excess electricity corresponds to the total annual consumption of domestic electricity for 45,000 homes, based on figures from Statistics Sweden*.

Head of Energy: Three major benefits of electricity generation
Södra’s own electricity generation and excess electricity play a key role in production stability and value generation for Södra’s members.

“Electricity generation at Södra’s pulp mills creates three major benefits: our members get more value for their forest raw material, our production is robust, and we are supporting our local communities with a continuous supply of green electricity. Electricity generation has played a particularly important role during the winter, when energy prices could otherwise affect the stability of production in our mills,” said Henrik Brodin, Head of Energy at Södra.

Making use of a by-product
The electricity from Södra’s three pulp mills is a product of resource efficiency. It is mainly generated by using the energy in black liquor, which is a by-product of the pulping process. From this energy, steam is produced that is used to drive the turbines which, in turn, generate electricity. There have been turbines at Södra’s pulp mills since 1958 and they have been improved in line with development. Södra currently has a total of nine turbines in operation.

“It is important for Södra to be self-sufficient in electricity. Our production processes require a lot of energy, and by using turbines, we are taking our responsibility for energy and much more. The energy business has been a priority for Södra for many years, and will remain so. The key to a strong energy business is to always maintain a central focus on energy and resource efficiencies. We will continue to invest in our energy efficiency,” said Andreas Martinsson, energy strategist at Södra.

In 2021, Södra Cell Värö generated 770 GWh, while Södra Cell Mönsterås generated 680 GWh and Södra Cell Mörrum accounted for just over 300 GWh. In addition to electricity, Södra delivered nearly 4 TWh of solid biofuels to power plants in electricity price areas 3 and 4 and delivered excess heat from its processes to the district heating networks of Varberg, Karlshamn and Mönsterås.

*According to figures from Statistics Sweden, normal electricity consumption for a home that does not use electricity for heating is about 5,700 kWh per year.

Voith’s digital solution package OnEfficiency.Strength, installed at Smurfit Kappa's Hoya mill in Lower Saxony in 2021, is showing very positive results from the first day. With virtual sensors and predictive control, OnEfficiency.Strength reduces the amount of starch applied while maintaining defined quality standards – a step that is leading to significantly lower costs and more sustainable paper production. The Hoya project is representative of how the two companies Voith and Smurfit Kappa are working together to drive digital transformation in the paper industry.

• The advanced process control system OnEfficiency.Strength has now been put into operation at the Hoya, Germany, site after a short installation period
• The solution from the Papermaking 4.0 portfolio ensures lower starch consumption, leading to significant cost savings and more stable paper quality
• The successful installation is a result of the strong cooperation between Voith and Smurfit Kappa and another important step towards more sustainable and efficient paper production with digital applications

"We chose Voith's digital solution approach because it offers significant cost savings with the latest technologies and pays for itself in less than a year," says Gerold Buck, Manager Operations at Smurfit Kappa Hoya. "With the implementation of OnEfficiency.Strength, we are successfully continuing our innovation and digitalization strategy while paying towards our sustainability goals." 

In the first step, Voith had conducted a value-add assessment that identified optimization potential and significant cost reductions for production with the help of digital technologies. Subsequently, Voith experts analyzed all relevant process, laboratory and production data from the last few months, checked for anomalies and defined a control concept based on this. For smooth data exchange and efficient commissioning, the plant was also connected to the Voith OnCumulus Cloud. In addition, the personnel received training at an early stage in order to operate the application optimally. After the quick installation and start-up, OnEfficiency.Strength immediately showed potential savings in starch application.

"Due to rising raw material prices and highly competitive pressure, paper manufacturers are increasingly looking for ways to further optimize their production facilities and save costs - digital solutions can make a valuable contribution here," says Maria Knauer, Global Product Manager Efficiency Solutions at Voith. "OnEfficiency.Strength continuously monitors all relevant quality parameters during the manufacturing process and automatically regulates the appropriate settings. Smurfit Kappa thus saves costs and resources in production every day in a simple and automated way. We see great potential to integrate OnEfficiency.Strength at many more plants worldwide." Smurfit Kappa is also considering installing the digital solution from the Papermaking 4.0 portfolio at other sites based on the results of OnEfficiency.Strength at Hoya.

With the "PAPER IS ON" campaign, Voith highlights the focus topics of the Papermaking 4.0 digital product portfolio: full-line supplier, efficiency, sustainability, cloud solutions, automation and innovation. Learn more and visit our homepage: voith.com/PaperIsOn.

About Smurfit Kappa
Smurfit Kappa, a FTSE 100 company, is one of the leading providers of paper-based packaging solutions in the world, with approximately 46,000 employees in over 350 production sites across 36 countries and with revenue of €8.5 billion in 2020. The company is located in 23 countries in Europe, and 13 in the Americas. Smurfit Kappa's products are produced from 100% renewable energy, improving customers' environmental footprint.

About the Voith Group
The Voith Group is a global technology company. With its broad portfolio of systems, products, services and digital applications, Voith sets standards in the markets of energy, paper, raw materials and transport & automotive. Founded in 1867, the company today has around 20,000 employees, sales of € 4.3 billion and locations in over 60 countries worldwide and is thus one of the larger family-owned companies in Europe.

The Group Division Voith Paper is part of the Voith Group. As the full-line supplier to the paper industry, it provides the largest range of technologies, services and products on the market and offers paper manufacturers holistic solutions from a single source. The company’s continuous stream of innovations facilitates resource-conserving production and helps customers minimize their carbon footprint. With its leading automation products and digitalization solutions from the Papermaking 4.0 portfolio, Voith offers its customers state-of-the-art digital technologies to improve plant availability and efficiency for all sections of the production process.

Tissue papers are usually intended for the hygienic-sanitary market and, precisely for this reason, their most requested characteristics are softness and bulkiness. However, there are other important properties that depend, above all, on the type of fibers used and their processing.

In the production of Tissue we use short and long fibers: the former confer qualities such as softness and silkiness, while the latter reinforce and give strength to the structure of the web. The technological level of both the machinery and the process used for the production of Tissue papers also have a great impact on the final quality of the product. In short, with the right raw materials and chemical additives, combined with dedicated cutting-edge machinery, it is possible to produce a perfect Tissue paper for top-of-the-range hygienic products.

So let's see in detail what are the five main and essential properties that quality Tissue must possess.

Bulkiness

The bulkiness is defined as the volume occupied by a given weight of paper. This is an important property, as it is closely correlated with absorbency and softness, and is mainly determined by two factors: the production technologies and the quality of the fibers used.

To obtain a high bulkiness in the production phase it is possible to use advanced technologies such as, for example, the Through-Air Drying process (or TAD), in which the wet pressing phase is reduced to minimum in favor of the drying operations that take place in the dryer section of the paper machine. In addition to production technology, other factors determining bulkiness are the use of lower pressure in the press nips, less intensive refining of the fibers and the creping of the paper.

As regards the type of fibers to be used, to obtain a high bulk it is recommended to prefer high-yield cellulose pulps, rigid and less subject to collapse thanks to the higher lignin content and lower porosity.

Absorbency

Absorbency is a fundamental property for any Tissue product dedicated to drying liquids. The sheet must therefore have both a high absorption speed, in order to effectively carry out its drying action, and a high liquid-holding capacity, to remove as much liquid as possible. Absorbency is given by the type of fiber used, the refining operations, the creping performed, the layers present in the final product and the additives used.

Strength

The Tissue paper sheet, in its life cycle, is subjected to significant stresses during production operations, in the converting phase and, finally, during use by the consumer. Hence the need to obtain a sheet with an adequate level of strength, given by the combination of three factors:

• strength and arrangement of fibers in the sheet;
• level of molecular bond between the fibers themselves;
• presence of strength additives.

Specifically, the first two factors depend on the process variables and the type of raw material used, while the use of additives is a widespread practice to add further strength to the fibers.

Wet Strength

Some Tissue products, such as kitchen paper, must be resistant even when wet, and this characteristic depends on the level of molecular bond between the fibers they are made of. In order to maintain the wet strength of these products as much as possible, additives can be used to supplement or replace the hydrogen bond of the fibers. In this way, it is possible to ensure that the Tissue paper maintains up to 50% of its dry strength when wet

Softness

Softness, while still being a subjective measure based on individual perceptions, is a very important requirement and sought after by consumers, especially as regards products dedicated to the hygienic-sanitary or personal care markets. Furthermore, the perception of softness does not depend only on touch, but also on sound and visual perceptions such as color (the degree of whiteness) and noise at the moment of tearing.

Softness is usually divided into surface softness, related to the velvet-like feeling to the touch, and bulk softness, which is an indication of the ease with which the paper yields when crumbled.

How to maintain the 5 properties of Tissue at the end-of-line thanks to A.Celli solutions

These five qualities, obtained during the production process of the paper sheet, must also be preserved in the subsequent phases, from the winding of the Jumbo rolls up to the shipment of the final reels to the converter. This is why A.Celli offers its customers a wide choice of winders, unwinders and rewinders of the E-WIND® range able to adapt to any production requirement in terms of speed, width and weight, with specific focus on bulky Tissue paper characterized by high crepe ratios.

Would you like to know more? Download our free content “How to manage soft Nonwoven and bulky Tissue paper”!