magazine
Edito
PAPER MIDDLEAST pulp, paper, tissue
The Magazine dedicated to the Pulp, Paper and Tissue Industry in the Middle East
N°27 - Autumn 2015 Head Office / Publisher ENP SA info@groupenp.com 36, rue Stanislas Julien - 45000 Orléans France Tél. +33 238 42 29 00 Publisher STÉPHANE RICHARD stephane.richard@groupenp.com Editor Lebanon RIMA DIB rima.dib@groupenp.com Correspondants Syria AHMED AL SLEEBA ahmed.sleeba@groupenp.com Jordan RAMI HOURANI rami.hourani@groupenp.com Advertising Middle East rima.dib@groupenp.com Tel: +961 32 24 953 International Advertising STÉPHANE RICHARD stephane.richard@groupenp.com FRANÇOIS HÉNIN francois.henin@groupenp.com Tel: +33 238 42 29 00 Fax: +33 238 42 29 10 Graphic Designers ELHAM EL MASRY GHALI SIMON & PARTNERS Subscription MATHILDE SEVESTRE mathilde.sevestre@groupenp.com
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n this issue of Paper Middleast, we are going to shed the light on Gemdoubs mill, a newly acquired French company by the Lebanese Gemayel Industrial Holding SAL. The 130 years old mill has an area of approximately 130,000 sqm and produces testliner, fluting and cardboard consumed mainly by the local market. Dr. Fady J. Gemayel owner of Gemdoubs, spoke about the acquisition, the current and future plans at the mill, the actual situation of the paper industry, also on the Lebanese industrialists and young graduates. Elected President of the Arab Federation for Paper, Printing and Packaging Industries, Dr. Gemayel believes that it’s possible to foster the interests of the paper industry in the region, and develop attractive opportunities where potential can be realized when joining forces. Another section of this issue will be dedicated to introduce to our readers some of the paper industry experts presenting products and systems to help resolve issues and improve the production process and the quality of the paper/tissue/board produced.
emtec Electronic GmbH in the article called: “Predicting the behavior of paper and board surfaces during gluing, printing and coating processes” noticed that certain specifications based on standard measurement methods are needed for paper and board while being converted (glued, printed or coated) in order to assure the required final quality of the finished product, though converting problems still occur frequently and the reason is not certain. “Optimization of Tissue Machine with Runtech’s solutions for energy savings, runnability and quality” is another article by Runtech Systems that has focused in productivity solutions for the paper industry. It gives solutions for energy saving, for optimization of the machine runnability, and solution to improve the quality, and vacuum systems, also tips on a fast recovery from paper breaks on tissue machines. Runtech is well known for being a reliable supplier for different kinds of dewatering solutions for tissue machines as well.
ISSN : 2264-606X Diffusion : 3.000 ex. Algeria, Bahrain, Egypt, Iran, Irak, Jordan, Kuwait, Lebanon, Morocco, Oman, Qatar, Saudi Arabia, Syria, Tunisia, United Arab Emirates, Yemen www.PaperFirst.info
Official Media Partner
Following is the entitled article: “Solving guiding problems on forming fabrics”; a paper explaining the principles of forming fabric guiding giving the papermaker tips on how to solve systematically guiding problems. This paper has been presented by Marcel Lensvelt, Managing Director of Feltest Equipment BV. Together, we are going to discover each of the mentioned topics, hoping you enjoy the reading!
Rima Dib rima.dib@groupenp.com papermiddleast 3
Advertisers Index Emtec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17, 60 Hello Baler Machinery . . . . . . . . . . . . . . . . . 35, 58 PaperME 2015 . . . . . . . . . . . . . . . . . . . . . . Cover 3 Plastics & Paper . . . . . . . . . . . . . . . . . . . . . . . . . 38
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Runtech . . . . . . . . . . . . . . . . . . . . . . . . . . . Cover 2 Wenrui Machinery (Shandong) . . . . . . . . . . . . . . . 7 Xerium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Contents
Paper Middleast 27 Autumn 2015
News
Technology
6
Al Rajhi Industrial Group to invest in new 2,000 m/min tissue machine in Riyadh
18
6
A.Celli Paper : Great satisfaction for the rebuild of a rewinder at United Paper Industries Co. (UPI)
Predicting the behavior of paper and board surfaces during gluing, printing and coating processes (By Emtec)
24
Xerium : New Roll Production and Services Plant in Turkey
6
Sotipapier and the rebuilt of its PM2 at Belli mill
8
; OL Ä YZ[ VĄ JPHS WYLZLU[H[PVU VM *HY[PLYL KP Trevi to the Middle East market
9
Process Optimization and Quality Assurance in Production and Converting
10
PCMC to supply Amica Unica line to MPI, the tissue converting company in Dubai
10
Pöyry awarded extension to owner’s engineer services assignment for Ras Al Khair project
11
Al Oula Paper Manufacturing Company and the successful start-up
11
PAPCEL will deliver a new line for tissue paper to Saudi Arabia
Tissue 27
Optimization of Tissue Machine with Runtech’s solutions for energy savings, runnability and quality
Machine Clothing 32
Solving guiding problems on forming fabrics
Events 36
Paper Arabia with more than 10,000 visitors From 14 to 16 September 2015
Report >> Gemdoubs (Lebanon/France) 12
The Gemayel brothers and the new overseas paper mill Gemdoubs!
papermiddleast 5
News
SAUDI ARABIA
Al Rajhi Industrial Group to invest in new 2,000 m/min tissue machine in Riyadh Gulf Paper Industries Factory, affiliated with Al Rajhi Industrial Group said it will invest in a new tissue production line. The new line features the latest technology with 5.6 m trim, 2000 m/min tissue machine to be located near Riyadh, Kingdom of Saudi Arabia. The start-up of tissue line is planned for the second quarter of 2017. It will produce 60,000 tons per year of high quality facial tissue, handkerchiefs, toilet paper and toweling grades using virgin fiber as raw material. Gulf Paper Industries Factory, one of the leaders in the paper industry in Gulf region, was established in the mid 1990s to serve the region with several paper and tissue products. Source: RISI
duction performance. Thanks to the close collaboration and synergies in experience created between the A.Celli team and UPI technicians, the new slitting unit was already operational in July. The customer’s open willingness to collaborate together with the expertise shown by our team made start-up fast & easy, with just a little over thirty hours (34) of stoppage of the unwinder – the very minimum amount needed for a rather critical replacement such as this one. The customer’s satisfaction was confirmed by their words : “The advantages of the rebuild are clearly evident : thanks to the new brake system with load cells, winding quality is uniform and the roll is more compact than before ; the cut is very accurate and the rewinder’s speed has increased by 20%. We are totally satisfied with the job done. A.Celli has supported and guided us through this journey, serving us impeccably. We will continue working with this company, assessing further modifications and developments on the rewinder, or in the event that other needs from our paper mills arise.” An important confirmation and a great vote of confidence for A.Celli Paper S.p.A., who is once again acknowledged as an excellent partner capable of satisfying customers with highlevel services and optimal results in terms of machine performance.
KUWAIT
A.Celli Paper : Great satisfaction for the rebuild of a rewinder at United Paper Industries Co. (UPI) Great results for the rebuild of a rewinder completed by A.Celli Paper at the UPI facilities in Kuwait. Initially, the project entailed replacing the old slitting unit and updating the tension control system. In a subsequent phase, the intervention was extended with the addition of a new unwinder with brake and load cell system. This newly defined project, which got under way at the beginning of 2015 and was shipped in April, obtained great results in terms of pro6 papermiddleast
TUNISIA
Sotipapier and the rebuilt of its PM2 at Belli mill Tunisian group Sotipapier (Société Industrielle du Papier et du Carton) placed an order with the company Allimand to receive a NAOS shoe press to rebuild its Kraft PM2. Allimand performed a comprehensive study and a complete analysis on the PM2 offering the rebuilding of the press section and the dryer part of the machine at Sotipapier’s mill. This contract saw the light following the tight relationship established between the two com-
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panies and the trust put in Allimand to carry out these kinds of projects. Sotipapier Group’s kind of investments implicated the expansion of manufacturing Kraft paper, increasing the total production on PM2, and improving the machine’s efficiency and overall performance. The good forecast of the Kraft paper in the local and in the neighboring markets, the exceptional position of Sotipapier at those markets, and the expertise of the French company Allimand in the field of wrapping paper, made this investment a major issue for Sotipapier Group. To resolve the paper machine main problems and improve its energy efficiency, Allimand undertook a complete press section rebuild by streamlining the sheet path, refurbishing some of the existing equipments, and by mounting an Allimand NAOS shoe press with a linear pressure of 1200kN/m. This equipment, ideal for wrapping paper, increases the dryness of the sheet before it is transferred to the dryer section. This reduces sheet breaks and widely optimizes the steam consumption in the dryer part. In addition to the reconstruction equipment of the press section and the dryer part, the order included the replacement of all doctor, siphon and steam box assemblies with certain existing elements of the dryer part being obsolete and inefficient. It also included all the necessary auxiliary equipments; control system, hydraulic system, piping, and wiring in order to correct the runnabilty of the machine. To enable the assembly and maintenance of the shoe press, Allimand installed a large gantry crane. In June, and as scheduled, the machine was stopped for 14 days to enable the installation and commissioning of the supplied equipments, the gantry crane having previously been installed. 8 papermiddleast
The delivery process comprised the installation of all provided equipments, the supervision and the start-up as well as the comprehensive training to familiarize the machine’s operators with the totally new equipments. Following the machine start-up, the Sotipapier operators will now become familiar with the new production requirements, while having the security of being assisted remotely by Allimand specialists if needed. Indeed, a link allows an Allimand control specialist to control all parameters of the new equipment from a distance and perform troubleshooting in the case of anomalies undetected by the mill personnel. On this basis, Sotipapier Group will strengthen its position on its market and has the target of an identical project for the second paper machine at the Belli mill, which is the paper machine number 3.
MIDDLE EAST
;OL Ä YZ[ VĄ JPHS WYLZLU[H[PVU VM Cartiere di Trevi to the Middle East market
The new management of the Italian paper mill specializing in the manufacture of packaging paper, coreboard and cardboard, met with customers, current and potential, on the occasion of Paper Arabia 2015, the most important fair of the paper industry in the Middle East, held in Dubai last September . On Cartiere di Trevi stand, exposing a selection of the main products staging in strips, nume-
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rous visitors had the opportunity to examine all the potential of the company in terms of specific offers. In particular was shown how now it’s possible realization of tailor–made product. Thanks to CT Lab, a special service using a team of specialists in the paper and its derived products field, created for fully understand the technical needs of customers, the company is now able to realize a ‘unique’ product for the customer, obtained from the crossing of all the information requested to confer it the best industrial runnability: the final application of the paper and paperboards, the relative basic composition and the traditional technical characteristics.
Since the beginning of the new millennium, the business strategy of Cartiere di Trevi has seen moving a significant part of sales towards exports activity. After developing business relations in European countries, the company began to work with some of the most important producers of tubes&cores and corrugated packaging of Saudi Arabia, the UAE and Oman, and now, thanks to the appreciation received from existing customers, Cartiere di Trevi attempts to conquer new market share in the Middle East. Cartiere di Trevi produces about 62,000 tons / year, in reels, strips and sheets splitted into the following product lines: packaging paper, kraftboard, greyboard, whiteboard, colored board, laminated board. All products are made exclusively with recycling waste paper FSC certified.
MIDDLE EAST
Process Optimization and Quality Assurance in Production and Converting emtec Electronic at Paper Arabia and Paper Middle East This year emtec Electronic will be present at the “Paper Arabia 2015” in Dubai together with the company GIG Chemie – the representative in the Middle East region. From September 14th until 16th, the companies will present different paper testing equipment at booth no. C400 and C401. Additionally, both companies will attend the “Paper ME 2015” from October 22nd until 24th in Cairo. In the wet end of the paper production process it is extremely important to have detailed information about the charges of particles in the pulp suspension, which can be determined by the CAS Charge Analyzing System. emtec Electronic will actually introduce its new CAS touch!, which is smaller and much lighter than ever before (hand luggage size). It is the latest state-of-the-art, has a touch screen and is ready to use without assembling further parts. Moreover, the knowledge about the surface charge of pulp fibers is also essential, which can be measured with the FPA Fiber Potential Analyzer. In addition to the wet end, it is necessary to get information about the quality of the base and final products. This can be achieved with the EST12 Surface & Sizing Tester, which will be presented in Dubai and Cairo. It characterizes the process-relevant surface parameters of paper and board in order to predict its converpapermiddleast 9
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ting properties. Additionally, the TSA Tissue Softness Analyzer will be shown, which gives reliable and objective information about the “hand feel” and different softness parameters of tissue products. In summary, the application of all these measuring devices leads to the optimization of the production and converting processes to gain the best possible quality at the lowest possible costs.
DUBAI, UAE
PCMC to supply Amica Unica line to MPI, the tissue converting company in Dubai The first Amica Unica Line, which is a further evolution of the Amica Matrix concept, has been selected by Metropolic Paper Industries (MPI) for the Middle East market. The new machine design is based on the innovative rewinding concept, DUAL GEOMETRY: a variable system that allows converting any kind of rolls from a 90 to a 350 mm diameter product. Simply, just one converting line is able to transform itself in two configurations, maintaining the main features of each process, and guaranteeing top quality finished product: soft and perfect consumer rolls, solid and excellent industrial products. This new equipment will allow MPI to diversify its product portfolio and easily switch from one configuration to another in only 15 minutes. Amica Unica, is the rebirth in winding technology. Metropolic Paper Industries (MPI) is an independent division of the Omarzay Group that was formed in 1956. The Omarzay Group has grown into a thriving group of companies with operations in Dubai, U.A.E., Peshawar, Pakistan, and Kabul, Afghanistan. 10 papermiddleast
Metropolic Paper Industries (MPI) manufactures tissue paper, kitchen rolls, napkins, toilet rolls, etc… Paper Converting Machine Company (PCMC) was acquired by St. Louis based Barry-Wehmiller Companies in 200. The company employs more than 5000 associates at 11 interactive, yet independent divisions located around the globe. Barry-Wehmiller is a $1.5 billion global capital equipment and engineering consulting company. It’s a world-leading supplier of packaging, corrugating, and paper converting technology, as well as engineering consulting services across a broad spectrum of industries. Source: RISI
SAUDI ARABIA
Pöyry awarded extension to owner’s engineer services assignment for Ras Al Khair project The Saline Water Conversion Company (SWCC) has awarded Pöyry with a two year extension to the owner’s engineer services assignment for the Ras Al Khair power & desalination plant in the Kingdom of Saudi Arabia. The project started in November 2010 and is scheduled to achieve full power and water production by the end of 2015. Pöyry will then continue to support SWCC to finalise the project until the preliminary acceptance by the client in May 2016 and subsequently to act as warranty engineer for the owner until May 2017. Pöyry’s scope includes the design review, project management and site supervision on behalf of the client. Pöyry currently has over 60 employees on site supporting the construction and commissioning of the plant. The Ras Al Khair plant is a landmark project for SWCC. It is the largest of its kind in the world
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- a combined power and desalination plant converting more than 1 billion litres of seawater into potable water each day. Along with a new water transportation pipeline, it transforms the picture for potable water in Riyadh, one of the world’s fastest-growing and most water-stressed cities. The Ras Al Khair plant not only produces water, it also produces 2 400 MWe of electricity for the Eastern Province of Saudi Arabia. «Pöyry has a long-standing relationship with SWCC going back some 30 years. As one of the world’s leading power engineering companies, Pöyry is proud to support our clients to succeed with important projects such as Ras Al Khair». says Floris van Straaten, Pöyry’s Regional Director in the Middle East for Thermal Power. The value of the order is not disclosed. The order will be recognised within the Energy Business Group order stock in Q3 2015.
KUWAIT
Al Oula Paper Manufacturing Company and the successful start-up Al Oula Paper Manufacturing Company successfully started up its production on the machine on 17 September, 2015, witnessing the creation of the first jumbo roll. Located in Meena Abdullah, Shuaiba in Kuwait, the mill is to produce various grades of paper such as fluting, liners, and Fax & copy paper with 200 tons of goods per day. The main production line is supplied by Voith Germany including up-to-date technologies, while ABB introduced its latest automation and drives technology.
The fully equipped line of production includes 4 Scanners, double coaters, super calenders on a built area occupying 25,000 sqm approximately. The start up on the machine went as scheduled giving beautiful result, management explained, and the project cost around 15,000,000 Kuwaiti Dinars (approximately 55 million US Dollars).
SAUDI ARABIA
PAPCEL will deliver a new line for tissue paper to Saudi Arabia At the end of September 2015, the PAPCEL Group signed another contract, this time with a customer from Saudi Arabia. A new paper machine with all the accompanying technologies for production of tissue paper will be delivered to a leading industrial holding. The line will produce papers for production of napkins, paper towels, tissues and toilet paper. In addition to delivery of machinery and equipment, the contract also includes engineering services, delivery of electro installations and a turnkey machine line assembly. So far, this is the largest delivery of the PAPCEL/ABK Group to the Middle East. The customer will be supplied with modern technology machines with hydraulic headbox and “Crescent Former” technology. At the end of September 2015, PAPCEL exceeded the magical revenues limit of one billion Czech crowns. The company reached the highest revenues level in its history, thus exceeding all previous records. The second half of the year has been the most successful period for the company, not only in terms of newly concluded contracts, but also by opening new production premises in Italy. The company’s plan is to reach the total of 1.59 billion CZK in revenues this year.
papermiddleast 11
Report
>> Gemdoubs (Lebanon/France)
The Gemayel brothers and the new overseas paper mill Gemdoubs!
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Gemayel Frères SAL produces packaging material and corrugated cardboard since 1956. The company was the first to introduce paper and cardboard recycling to Lebanon in 1929.
Gemdoubs owners and major partners is Gemayel Industrial Holding SAL belonging mainly to Nabil J. Gemayel and Fady J. Gemayel, both being co-owners at the Lebanese companies: Gemayel Frères and Solicar.
While Solicar SAL (Société Libanaise de Carton Sal) was founded in 1964, and is a major paper recycling company in Lebanon producing paper and covering different markets and industries such as the containerboard industry, the cardboard for the bookbinding industry, the food industry, the agricultural industry and others...
ocated in Novillars; a town in the Doubs Department in the Franche-Comté - eastern France, Gemdoubs is the new acquired paper mill by the Gemayel Industrial Holding SAL.
Gemdoubs on the light The acquisition of Gemdoubs’ mill was completed in July 2013, the original company having more than 130 years of age. During those long years, the company witnessed a sequence of managements, and different types of production and machineries. The mill’s machines produced testliner, fluting, regular paper and regular liner board. 12 papermiddleast
Today, the mill works with one machine that was put back into production in September 2013. The basic machine is mainly French and German. Bellmer of Germany supplied the latest machine’s addition, while Black Clawson, Andritz and Sulzer provided the mill’s stock preparation. The mill uses 100% recycled paper in the production process, and has an area of approximately 130,000 sqm. The machine produces testliner, fluting cardboard, and paper from 120 to 200 g. Machine’s specification Machine 1 Paper width on pope reel (meter)
3.40 cm
Operating speed (m/min)
From 350 to 500
Basis Weight Range (GSM)
120- 200
Instruments
Measurex
Scanners
Measurex
Stretches
Bellmer
Machine’s renovation After the new acquisition, the Gemdoubs management decided to undertake a partial machine re-hauling. The project included in addition some upgrades on parts of the machine; the stock preparation mainly. This major re-hauling project was undertaken by Bellmer and Andritz. Both, the re-hauling and the upgrading took place between 2013 and 2014, for a 3 months’ period of time. In that event, the machine’s performance and the production capacity were improved, and Gemdoubs produces today between 285 and 300 tons per day of paper products. Current and future projects Gemdoubs’ scope of expansion doesn’t stop here. The management is considering increasing the capacity of the paper machine as part of the plan, and is going to work on a phase of consolidation and optimization of the production process, as well as on optimizing the product itself; a part will be specifically dedicated to the product mix. Another plan is under the go which is the cogeneration mill that will be operational late 2017. The cogeneration mill will produce electricity to the city of Besançon; that is 7 KM away, and it will at the same time, supply steam to the Gemdoubs mill itself. Gemdoubs’ vision: Competent team and targeted market Gemdoubs’ vision and strength is defined by being a “focused paper producer”. The management presents dedicated products and stresses upon few products giving particular attention to their customer satisfaction. Being a serious player with a decent volume to Europe, Gemdoubs strives to have a continuous and excellent contact value with its clients who are coming from different backgrounds. In one word, Gemdoubs offers an excellent product emphasizing on customer relationship boosting the excellence in operation! papermiddleast 13
On the other hand, a well trained and professional team formed by more than 60 French, work for the company. Those employees follow continuously specialized and particular trainings related to their position and function in the company. With a clear vision and a dedicated team, Gemdoubs enters the market with steady steps. While the major market consumption goes mainly to France followed by Germany, Holland and Italy, the overseas sales go to West Africa and the Middle East countries. Noting that in a highly consuming market, the highest consumption percentage of production goes to the French market, it reaches around 80% of the total of production, while the export markets take the rest (20%).
pean standards where experts retrieve them for additional treatment, management declared. It is important to mention that Gemdoubs is keen and circumspect to maintain the same interest and protection of the surrounding environment translated through different activities within the mill. Noting that, the company was awarded by the French Association “Ligue pour la Protection des Oiseaux, LPO”. LPO is the French representative of the BirdLife International Group.
Water & waste treatments and energy consumption Being a friendly company to the environment, Gemdoubs’ mill has a very advanced effluent water treatment system based on a biological/ technical treatment in an aerated Laguna. This Laguna uses a sophisticated biological system relying on natural background and resources. This water treatment project is developed with the local university. As per the waste treatment another key matter in the production process, recovered paper is sourced in France thru several French companies specialized in the field. The waste generated by the company is within the range of Euro14 papermiddleast
The Gemdoubs’ mill is working on gas, while the electricity is bought from the local companies, a main reason why the Gemdoubs’ management is looking forward to the installation of the cogeneration plant which will be generating energy from wood bought from the region of Franche-Comté. Saying so, it is expected that the cogeneration plant will reduce the mill’s bill by 20%, and is estimated to be on the run by the end of 2017. Being a fully operational mill, and working firmly by the international standards since the Gemayel’s acquisition, the Gemdoubs management is expecting to get back the ISO Certification (ISO 9000 for Quality Management, and ISO 14000 for Environmental Management) in few weeks time.
Dr. Fady J. Gemayel conveying the past and present Giving a briefing on the Group and Gemdoubs’ acquisition, Dr. Gemayel explained that Ge-
mayel Group has pioneered the recycling and packaging industry in Lebanon and the Middle East area in 1929.
additional opportunities outside our mother land.” Dr. Gemayel stated. On the other hand, being confident in our Know-How in our activity which we have been focusing on, and building a professional team in Lebanon, it was normal that we’ve looked for investment opportunities overseas, and didn’t hesitate to operate in Europe itself where we are proudly dealing with prime international groups.
Ever since, the Group has been very active in Lebanon despite the very difficult situation it witnessed at times.
“We are an eighty five years “young” company! After operating in a very difficult environment in Lebanon particularly for industry, we were able to play a role with our fellow industrials in promoting packaging and in advancing Lebanese industry through its presence worldwide.
We provided innovative solutions and participated in boosting the image of “Made in Lebanon” through the presented products. Our products; the packaging, do accompany most of Lebanese manufactured products as well as agricultural produce.
We are proud as Lebanese to see our paper products and paper material exports reaching the world. Furthermore, several Lebanese companies working in the field do operate all over the world.
Hence, the company has developed several product lines, and proposed several technological processes under one roof, Dr. Gemayel added.
It’s a true Cedar network, a Cedar presence and extension that is proudly spanning around the globe!
The Group has introduced the F-Flute back in 2000, the Lito-laminated; providing innovative solutions for promotional items and POS materials (Point of Sales Displays), high graphic printing and high graphic post-print, as well as pre-print technologies in line with the group sister company that also produces labels for the customers’ needs.
I believe that Gemdoubs is an interesting company by itself, and it’s a door open for us to access the European market.
Being a true One Stop Shop provider of packaging solutions in Lebanon that has also set firmly its roots with the production of paper itself in Lebanon, made of the Group among the first totally integrated (paper production and corrugated packaging) companies in the Middle East. “Our dedication to Lebanon and to the Lebanese industry and agriculture in general, having been also extremely close to the Lebanese manufacturers and distributors, we had to find
As you know, in Solicar (Lebanon), we have made major investments developing the production of white tesliner, and we look forward to exporting it to Europe.” Dr. Gemayel affirmed. Overview on the current situation of the paper industry The paper industry has several aspects, and the impact of the digital world on newsprint has been already consumed, according to Dr. Gemayel. “One shouldn’t forget that the challenges of the modern life are promoting the need for paper packaging all over the world, and that the role papermiddleast 15
is expanding not only for logistics but also for promoting the products. F u r t h e r m o r e, corrugated packaging is also confirming its stands as the most preferred packaging all over Europe and the USA. Adding to that, the general interest in sustainability and instance on sustainability and green development has promoted the paper industry as it combines the usage of paper from renewable resources as forests re-management is the rule of the game in the industry preserving and nurturing our trees combined with the recycling of the products. This combination is a virtuous circle of a very interesting product which is paper packaging.” he clarifies. Dr. Gemayel’s positive view pushes him to believe in the promising future; he assures that the paper industry will live up to the new challenges of continuously providing innovative solutions! Dr. Fady J. Gemayel; President of the Arab Federation for Paper, Printing and Packaging Industries I have the privilege of being elected in a difficult situation prevailing across the Arab World. Nevertheless, this leads me to have a total respect for the players, and an admiration for their commitment and resilience. I am also confident that this network of confidence between the players across the region, can create an area of cooperation trying to foster the interests of our industry in the region, and to develop together attractive opportunities. Adding to that, I look forward to work for possible cooperation to develop new markets, to 16 papermiddleast
cooperate also in the complementarily of products allowing us to be more specialized producers, building one each other’s expertise and potential; rather than being generalists in this small competitive worldwide market. On the other hand, I don’t want to raise expectations particularly during this hectic period the region is going through, but I don’t want either to minimize and overlook the potential that can be realized when we unite our forces. Lebanese industrialists and the young generation Dr. Gemayel is confident that the Lebanese paper industry in general has proven today its resilience and determination to overcome all obstacles, defining the success of industrialists in Lebanon due to their engagement and perseverance in addressing most difficult issues building on excellent products, flexible approach, and honoring commitments despite all odds. For many, Lebanon is “not” a destination for industry, Dr. Gemayel added, but the Lebanese industrialist has proven to be a solid player capable of building on the traditional background we have in several activities particularly in the paper industry with an eye on the World. “We are proud to have capable team members who have overcome hard circumstances through flexible and innovative solutions, also who are capable to advance their groups in the future. And I firmly believe that the Lebanese industrialists, who have suffered a lot in the past, have become real experts in managing difficult situations. I am also confident that they will be seizing additional opportunities in the region. Let us not forget that the prospects of gas and oil will be also a game changer; leaving Lebanese companies with further opportunities! Moreover, we are blessed to have in Lebanon an exceptional young generation, and we are happy that on the 77th birthday occasion of our Group we have sponsored a Masters program in
paper technology offered by the University of Grenoble and the Lebanese University. These graduates are now highly active players in the paper and packaging industries. I am also very proud that the name of my father Joseph Habib Gemayel who has played a signiďŹ cant role in advancing the paper and packaging industries in Lebanon, which were put to an end due to his early death, that his name is associated with the program offered by those universities, and it contributes to the future of these brilliant graduates.â€? Dr. Gemayel announced.
Last but not least, I would like to thank you and your magazine for the positive image you are portraying in the region. To my colleagues in the Arab Federation for Paper, Printing and Packaging Industries I wish the best in these difďŹ cult moments. I am sure they will succeed despite all the many challenges we are facing. I can only tell them that together we are strong and we can develop further the Paper and Packaging industry in our region with vision, pride, and determination!
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Technology
Predicting the behavior of paper and board surfaces during gluing, printing and coating processes 1. Basics about specifications of paper and board Paper and board is generally further converted, i.e. glued, printed or coated, in order to assure the required final quality of the finished product. For an optimal runability during finishing or converting processes, certain specifications between producer and customer are agreed upon. Usually, these specifications are based on standard measurement methods like Cobb test, Hercules Sizing Test HST, Bendtsen/Gurley porosimeter, and Smoothness Beck. Although the agreed specifications of the produced paper and board are often met, frequently still converting problems occur and the reason is unclear.
2. Problems in converting processes and reasons for them It is therefore necessary to identify and subsequently to measure the paper parameters that are relevant for the converting process. Thereby, it is very helpful to understand the converting process of paper and board in detail. Main problems are the gluability, printability and coatability of paper and board. Highly simplified, the process of gluing, printing and coa-
Fig. 1: Schematic illustration of the gluing, sheet offset printing and coating process and the respective application of adhesive, offset ink and coating color onto paper/board surfaces
ting can be separated into three phases: inking, gluing and coating (fig. 1). This leads to the identification that primarily the surface parameters of paper/board are important for the converting processes, in particular surface porosity and surface hydrophoby/ sizing.
3. The missing ability of standard testing methods to solve these problems As described in chapter 1, there are several standard testing methods, which the specifications between producer and converter are based on. 18 papermiddleast
In the following there shall be described why these do not provide sufficient information respectively often even provide wrong information and thereby lead to unexplained problems during converting. As a comparison, testing results of the systems PDA.C 02 / EST12 will be presented. Emtec Electronic GmbH developed the modular measuring system PDA.C 02 Penetration Dynamics Analyzer and the EST12 Surface & Sizing Tester to determine the converting-relevant paper parameters.
3.1 Determination of surface porosity 3.1.1 Bendtsen porosimeter test Fig. 2 shows the simplified pore structure of a paper sample in z direction from top side and back side. At Bendtsen Porosimeter test, the air flow through the paper in z direction is determined by the sum of the effective pore areas (smallest areas) of all pores. Therefore, the Bendtsen test shows the same values from both sides, although in this example the surface pore structure is totally different from both sides.
3.1.2. Pda.C 02 / est 12 analysis The measurement with PDA.C 02 / EST12 can provide the correct information about the real pore structure on the surface of the paper/board. To characterize the pore structure, the device measures the change in ultrasound transparency during liquid penetration and as a number the parameter t95, which is the time point when the signal at the receiver is reduced from 100% to 95%, using a water-isopropyl alcohol mixture. This time point is usually in the range of milliseconds, meaning that it thereby characterizes the surface. The PDA.C 02 / EST12 test can prove the big difference between the two sides of the sample of fig. 2 (fig. 3). From the curve, it can be derived that there are big pores on the back side, as the signal decreases very quickly. On the top side, very small pores are detected due to the initial flat progression of the curve.
The pore structure/size on the surface can also be different from the internal part. The standard methods do not provide information about the surface pore structure.
Fig. 3: Characterization of the surface pore structure with the PDA.C 02 / EST12, using a water-IPA mixture as test liquid
Fig. 2: Schematic example of the pore structure distribution of a paper sample in z direction (cross section) and the air flow from Bendtsen porosimeter test, tested both from top and back side
3.2 Determination of surface hydrophoby / sizing 3.2.1. Cobb test On hand of two samples, first with high surface papermiddleast 19
sizing and low internal sizing and second in contrast with low surface sizing and high internal sizing, the issues of Cobb test shall be explained. According to the differently distributed sizing, the dynamics of water penetration are different. The penetration into sample 1 is first slow (high surface sizing), then fast (low internal sizing), and for sample 2, it is vice versa (fig. 4). The Cobb60 test measures the water penetration as total volume over 60 s. In figure 4 is shown the course of the water penetration as an “absorption over time” diagram. The area under the curve is the measure of the amount which can be absorbed within 60 s. Although the sizing is so different, after 60 s the same amount of water penetration is measured for both samples, wrongly saying the two samples have equal quality. The Cobb test does not provide separate information about the surface sizing and internal sizing, because it only gives an average value.
gives the correct information about the surface hydrophoby / sizing by determining the time point MAX, which is the time point of maximum transmission of the ultrasound signal, using water as test liquid. The comparison of the curves of the two samples measured with the emtec analyzer shows the difference in surface sizing and internal sizing. The later occurring time point MAX reflects that sample 1 is more hydrophobic / sized on the paper surface but less hydrophobic in the internal part, while it is the opposite for sample 2.
Fig. 5: Characterization of the surface hydrophoby/sizing with the PDA.C 02 / EST12, using water as test liquid
4. Application of the measuring technique pda.C 02 / est12 to solve these converting problems
Fig. 4: Schematic illustration of water absorption speed into two different samples and Cobb test evaluation
3.2.2. Pda.C 02 / est 12 analysis The measurement with the PDA.C 02 / EST12 20 papermiddleast
The PDA/EST measuring system enables measurement of process-relevant surface parameters of paper and board in the laboratory in an extremely easy and efficient manner. The innovative measuring principle is based on the assessment of the dynamics of ultrasound transparency of paper/board during liquid absorption. Such as in the real process, the mea-
surement of the interaction between test liquid and sample surface occurs during the first milliseconds, which is important for the characterization of the surface porosity, resp. seconds after contact, which is significant for surface hydrophoby/sizing. Appropriate test liquids are used to gain the desired information, and the relevant quality parameters are calculated automatically. The surface pore structure is characterized by the parameter t95, which is the time point when the curve reaches 95% (or 99%) of the ultrasound transparency after the initial contact time point 0, using a water-IPA mixture as test liquid (fig. 6). Surface hydrophoby / sizing is determined by parameter MAX, which is the time point of the curve maximum, using water as test liquid (fig. 7).
Fig. 6: Surface pore structure characterization
concentration has also an impact to the surface porosity and therefore to the ink/oil absorption. Therefore, next to measurements of surface porosity and surface sizing of uncoated paper, the measuring instruments PDA.C 02 / EST12 are also targeted at characterizing the binder concentration of CaCO3 coated paper by using acetic acid as test liquid.
5. Application example The following two examples shall be an evidence for the described problem of an insufficient or wrong information from measurements with standard testing devices. First example refers to a coating trial which was conducted on base board of the same grade, produced in the same paper mill. Both jumbo rolls ought to have exactly the same quality. Bendtsen and Gurley test showed identical values. Nevertheless, the coating trial failed and the reason was unclear. With the help of the PDA.C 02 / EST12 system, it was possible to see a difference of about 17 times in surface pore structure (fig. 8). The reason was that, due to the fact that jumbo roll 2 (t95 = 1.283 s) had an extremely closed surface pore structure compared to jumbo roll 1 (t95 = 0.074 s), the closed pore structure led to a non-optimal coating result and thus to the fail of trial target.
Fig. 8: Example of surface porosity characterization of coating base board with PDA.C 02 / EST12 Fig. 7: Surface hydrophoby characterization
A further opportunity to characterize the surface of CaCO3 coated paper/board: In the printing process, paper can have a propensity to so-called “linting”, which means that the CaCO3 pigments of the coating color are not sufficiently fixed by binder and can be ripped off the surface by the ink. The binder
In the second example a gluing problem was identified by a corrugated board producer. Although the two testliners were behaving differently in gluing, the Cobb60 values were the same. The PDA.C 02 / EST12 system opened the ability to understand why this happened (fig. 9). There was a difference of about 7 times in surface sizing between the two testliners. The water penetration into the surface of testliner 1 (MAX = 5.479) took much longer than into the papermiddleast 21
surface of testliner 2 (MAX = 0.807). However, the internal sizing is about the same, which led to the approximately equal Cobb values.
process optimization can be avoided and thus it is an extremely efficient tool for product and process optimization and to save considerably money, time, material, and man power.
7. Conclusions and outlook
Fig. 9: Example of surface hydrophoby characterization with PDA.C 02 / EST12
6. Measurement procedure and applications For a producer of paper/board, the first step should be to obtain detailed information from the converter about the problems in the converting process. Second step is to perform the measurements of the respective samples with the PDA.C 02 / EST12 and correlate the results with the information from the converter. The surface porosity as well as the surface hydrophoby are to be checked. In the third step, it is possible to prepare a data base with comparison of PDA/EST results of good/average/poor samples and thereby to determine needed specifications and to assure compliance with the specifications for QA and optimal process control. Reasons for malfunctions in the process can be easily identified in the event of trouble shooting and complaint management. By that, machine tests for the
22 papermiddleast
Bendtsen/Gurley and Cobb test are standard procedures, which have been applied for a very long time in the paper industry. All respective specifications are typically based on these devices and all the customers/converters require these values. However, it is increasingly realized that apparently optimal converting properties cannot always be guaranteed with these methods. Although in long-term it might change, in short- and medium-term probably the previous procedure will be continued, i.e. externally the specifications are agreed upon the basis of these standard devices. Producers and converters realize yet the immense opportunities in using the modern PDA/EST measuring technique for internal specifications, allowing a real prediction of the converting quality due to the measurement of the relevant surface parameters. With the help of the new technology, QC quality defects are identified early before delivery of the products, complaints and thus disputes can be avoided, the customer satisfaction is increased and costs can be saved. In the product/process optimization, the devices allow targeted control of the relevant parameters, which makes it possible to improve the product quality and also to reduce costs. emtec Electronic GmbH 04347 Leipzig www.emtec-papertest.co
Technology
Xerium: New Roll Production and Services Plant in Turkey Excellent product quality and machine LĄJPLUJ` UV^ H]HPSHISL SVJHSS` Xerium Technologies Inc., one of the global leading suppliers and the pioneer of paper machine clothing, roll and roll cover technologies has put its new state-of-the art rolls and mechanical services plant located in Çorlu, Turkey, into operation end of October. It is the first facility established in Turkey by any of the industry’s major global suppliers.
X
erium, which has conducted business in the region for many decades, has now built an indigenous supply capability. The centerpiece of the business start-up is a greenfield plant in Çorlu. It took over two years
24 papermiddleast
to design, build, equip and commission the new facility, which is equipped with state-of-the-art rolls und services machines, as well as information systems and supply chain interfaces (SAP technology platform).
Pictures above: View into Xerium’s brand-new plant in Çorlu, Turkey
Locally provided and locally optimized state-of-the-art technology For the first time ever, customers in the region will be provided with Xerium’s full suite of patented performance-enhancing product solutions as well as with dramatically quicker and more cost effective services. The company has also increased its field sales and service staff for the region to ensure superior mechanical services, roll covering capabilities and machine automation through its SMART® Roll sensor solutions. Importantly, its products and services will be delivered through a local workforce, familiar and respectful of local customs. The experienced team of factory-direct sales, service and operational personnel is highly motivated to transfer all of the company’s patented technology solutions and all of its best practices to the region and help customers to run their machines in the best possible manner.
Broad portfolio of products and services with high economic value for customers Xerium’s wide range of paper machine clothing
(Huyck.Wangner), roll & roll cover technologies (Stowe Woodward) and integral services with innovative products and solutions for all kind of applications for the pulp and paper, textile or metal industry is now available more or less “next door”. It provides not only highest productivity performance and best paper quality, but particularly increased efficiency and significant economic value. The product portfolio includes roll and roll covers for press, calander, size press, guiding or drive rolls applications – among them rubber, polyurethane or composite compound roll covers. They are available in a variety of surface structures, such as plain, blind drilled, grooved or blind drilled plus grooved. Additionally, Xerium offers balancing and grinding – last-mentioned is possible for all crowns. The full mechanical roll services include complete suction roll, journal and bearing service, added by nondestructive testing (NDT), repair of internal cooling systems and spreader roll repair. The services team is able to handle rolls up to 2.000 mm diameter, up to 10.000 mm length and up to 75 tons. papermiddleast 25
A further portfolio highlight is the SMART Roll Technology, Xerium’s patented, exclusive online nip load measuring system for single and double nip applications as well as suction press applications. Customers can gain by the direct local access from a number of benefits, mainly: • Very quick lead times • Less transportation time • Transport costs savings • Service support for trouble shooting • Permanent back-up by the Xerium EMEA’s team.
Xerium’s decision for the business start-up in Turkey is to provide customers in the region with world-class technology, short lead times and a local cost structure. At the same time it is a manifestation of both elements of the company’s long-term strategy focusing commercial success and cost leadership as well as targeting specific customers’ needs and specific machines with value-added offerings. As the paper industry is healthy and growing in this area, the company is convinced, that this commitment brings value to the whole region and helps customers to win in their markets and profit from the highly performing products and services.
Pictures above: Xerium’s local team supports customers in Turkey, Southeast Europe and the Middle East with the compony’s unique product and technology solutions, and customer support.
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Tissue
Optimization of Tissue Machine with Runtech’s solutions for energy savings, runnability and quality
T
hroughout its history Runtech Systems have focused in productivity solutions for paper industry. Whether it is energy saving, optimization of runnability or quality or fast recovery from paper breaks through quick tail threading, Runtech can provide a solution with guaranteed payback. Runtech supplies Ecopump TurboTM vacuum systems for the Tissue machines – the revolutionary blower technology that allows substantial operational cost savings in paper machine vacuum system. Runtech is also well known supplier for different kinds of dewatering solutions for both forming and press sections of any type of tissue machines.
Picture 1.Compact Ecopump EP500-700-S Turbo and new generation Ecodrop water separator.
Why should we optimize vacuum systems and dewatering in Tissue machines? In the Tissue machine, vacuum is necessary to remove water from the web, to clean the fabrics and felts, and to control the web run in the tissue machine. Each vacuum element in the machine, such as suction box and suction roll, needs certain amount of capacity for vacuum and flow. The needed capacity actually changes according to the felt life and type, paper grades, basis weights, machine speed etc. Traditional liquid ring pumps and fixed speed blowers cannot accommodate to the dynamic vacuum and flow needs, hence resulting always the waste of energy, which could be huge in some cases. In addition to the water, there are always fibers, chemicals, fillers and additives in the Tissue machine environment. If not separated thoroughly, these chemicals together with fibers, fines and water, will build up on the pump volutes and impellers and will erode the pumps, and eventually reduce efficiency or even cause damage to the vacuum pumps. Tissue production is water and energy intensive industry. Sustainable use of energy and water is highly related to the profitability and competitiveness between the producer in the Tissue industry. For sure, those Tissue producers with lowest papermiddleast 27
energy and water consumption will be more competitive under the intensive global competition. That is the main reason why one should always try to optimize the energy and water consumption. Undoubtedly, vacuum system in a tissue machine, which consumes very high share of total energy of the tissue machine and huge amounts of water, should be one of the first things on the list to be optimized.
Runtech vacuum system and dewatering audits As mentioned earlier, vacuum demand varies with different Tissue grades, felts and machine speeds, therefore a tailor-made solution with flexible and variable capacity can balance the supply and demand, hence result in both optimized dewatering and minimized power consumption. For those reasons Runtech is offering the professional vacuum system and dewatering audits for its customers.
Picture 2. Onsite vacuum system study is a key to successful energy and dewatering optimization. After the study project payback can be calculated accurate and energy saving is always guaranteed.
Runtech engineers have done hundreds of different kinds of vacuum system and dewatering studies and audits for the Tissue industry over the last 20 years. The results of those studies and audits together with the on-line EcoflowTM measuring results of the real-time dewatering are giving necessary information of the condition of your dewatering equipment, suction elements, fabrics and felts.
Ecopump TurboTM vacuum systems for rebuilt and Greenfield projects Based on the vacuum system audit Runtech 28 papermiddleast
can give recommendations for the Ecopump TurboTM vacuum systems. Ecopump TurboTM is the first variable speed and variable capacity vacuum blower which Picture 3.Vacuum system layout for the greenfield tissue machine is very makes it easy to simple with fully backed-up system. match vacuum and flow needs for the certain position, at certain time. By EcoflowTM, you can easily identify the exact vacuum and flow which Picture 4. Rebuild example. EcoPump levels lead to maxiTurbo replaces 3 vacuum pumps which is creating energy saving of 30mized sheet 60% and 100% water savings. dryness with less breaks, better profiles and lowest energy consumption, at certain position, at certain time. Through Runtech’s approach, Tissue makers can save 30-70% of energy compared to traditional liquid ring pumps. Besides the significant energy saving, Ecopump TurboTM is a totally water free vacuum system. Vacuum system rebuilt to Ecopump TurboTM system can be done during normal machine shutdown or even during machine running to avoid unnecessary losses because of extra shutdowns. Additional savings can be reached from the heat recovery because the temperature of exhaust gas from Ecopump TurboTM can be up to 160 degrees. Hot exhaust air can be used to heat process water, the building (i.e. false ceiling) or to preheat the gas burner air. In careful consideration of build-up and erosion problems by water, fibre, fine, chemical, etc, the Runtech EcoDropTM water and drop separator has been specially developed to effectively separate them ensuring always reliable and effective vacuum generation.
The typical RunEcoTM process for a vacuum system energy saving and optimization rebuild project:
The typical RunEcoTM process for an energy saving vacuum system Greenfield project:
Dewatering and doctoring solutions for Tissue machines
sue machine efficiency and reduces the energy consumption in drying. An optimized and well working doctoring system contributes greatly in the efficient dewatering and subsequent maximized dryness after the press. It is widely accepted that nip dewatering is the most efficient and economical way to remove water at the press nips. However, in order to get the full benefit from nip dewatering, the press section doctoring and save-alls need to be properly designed to handle the increased water loads. It’s also very important for the press nip rolls to have high void volumes to facilitate the higher water load and enable that water will be removed from roll grooves and holes. Today, not only on highest speed Tissue machines, but also on medium and lower speed Tissue machines, the combination of nip dewatering and doctoring is becoming more and more widely applied for higher dryness, energy saving and better profile.
Too much water in the Tissue sheet causes low dryness after press and thus higher energy consumption in drying. Maximizing dryness after the wire and press sections improves Tis-
Picture 6. Felt dewatering optimization by using Ecoflow measurements. Total dewatering of PU-felt increased by 10% when vacuum level was dropped from -42kPa to -30 kPa. Picture 5. Press roll doctoring optimization gives a possibility to optimize the vacuum levels. Well-designed save-alls and doctoring will minimize rewetting, build-ups and misting.
In short, dewatering and doctoring are not only related to energy consumption, but they also have big effect on whole machine runnability, papermiddleast 29
efficiency and profitability, as well as the sheet profiles. Therefore, a well designed and operated dewatering and doctoring system is highly demanded. Runtech is one of the leading suppliers for the improved dewatering and doctoring solutions for the all kinds tissue machines. In many cases Runtech’s solutions can lead to a 1-3% increase in dryness after the press which saves considerable amount of energy in the drying (4-12% less energy). Runtech is combining its’ Tissue making knowhow with emerging materials and technologies which are well presented in Runtech’s latest dewatering and doctoring optimization solutions. With strong capabilities in carbon composite manufacturing, compressed air and vacuum management, Runtech developed the exclusive AirBladeTM technology to improve roll cleanness, sheet dryness and sheet profiles.
Owing strong knowhow in composite manufacturing, Runtech provides compact, reliable and almost maintenance free solutions to doctoring improvement, even in those most challenging doctoring positions. The CompoAdaptTM doctor holder, CompoDocTM doctor beam and WingBladeTM composite doctor are the latest innovations. The typical process for a dewatering and doctoring optimization project:
Fit-for-purpose vacuum system and efficient doctoring and dewatering solutions for forming and drying sections are the fundamental base for the good energy efficiency and low cost Tissue production.
ProfiVaneTM composite flow sheet for headbox
Picture 7. All Runtech save-alls are designed for Ecoflow measurements. Both uhle box and save-all water flows should be measured to get clear understanding about the press section dewatering.
In order to get the full benefits from increased dewatering, an online dewatering monitoring, efficient water discharge and rewet prevention are necessary. Runtech EcoflowTM, save-all and double doctors can perfectly match these needs. 30 papermiddleast
In addition to the most energy efficient vacuum systems and excellent doctoring and save-all solutions – Runtech has developed several other state-of-art carbon composite products in its’ advanced composite factory which is fully dedicated to the needs of paper makers. Due to the Runtech’s expertise in carbon composite manufacturing Runtech is one of the few suppliers in the world, which can supply carbon composite flow sheets to any headbox of any Tissue machine. Derived from our multidisciplinary expertise in both paper industry and composite technology, Runtech has developed its’ latest product ProfiVaneTM as a trouble free flow sheet for the headbox providing several benefits compared to
the old materials. Comparison between common PolyCarbonate and Carbon Composite flow sheets: PolyCarbonate
Carbon Composite
Water absorption
0.18-0.35
0.022
Tensile yield strength, Mpa
62
>1,500
Tensile module, Gpa
2.4
>75
Chemical resistance
Not to alkaline or solvents
Excellent
Comparing with traditional polycarbonate and other material flow sheets, ProfiVane™ owns several key competitive advantages: excellent dimensional stability, stiff and straight MDand CMD-profiles, excellent surface quality and very high wear resistance. In addition, thanks to excellent chemical resistance of composite, it is even unnecessary to remove and reinstall Pro-
fiVane™ flow sheets during head box washing – which eliminates the risk for scratches and/or damages of flow sheets during handling. Picture 8. ProfiVane™ flow sheets can be produced is all designs and sizes.
ProfiVane™ flow sheet are giving the following advantages for the Tissue makers: trouble free run with excellent sheet formation and improved MD- and CMD-profiles and clearly longer lifetimes of the flow sheets than any traditional flow sheets.
Picture 9. Some examples of the ProfiVane™ flow sheet applications for Tissue machines.
papermiddleast 31
Machine Clothing
Solving guiding problems on forming fabrics Edited and updated by Mr. Marcel Lensvelt, Managing Director of Feltest Equipment BV, based on an article of an unidentified author.
Introduction When a forming fabric doesn’t want to run straight it usually causes many problems and costs. In the worst case it actually runs into the machine frame and the fabric is completely destroyed. But also continuous strong guiding corrections lead to excessive fabric wear and hence high costs.
Figure 1A
This article explains the principles of forming fabric guiding and gives the papermaker tips on how to systematically solve guiding problems.
The principle of fabric guiding In the loop of each fabric there is one roll equipped with the task to keep the fabric running straight: the guiding roll. One side of the guiding roll, usually at the tending side of the machine, can be moved in the running direction of the machine. In figure 1 it is shown how the fabric will move when the guiding roll is pivoted. The fabric will always travel toward the side of the guide roll that it contacted first. In figure 1A this is the right hand side or drive side (DS) of the machine. In figure 1B the left edge of the fabric reaches the guide roll first and moves the fabric to the left or tending side (TS) of the machine. 32 papermiddleast
Figure 1B
The importance of friction The friction created between the guide roll and the forming fabric is the key of the guiding process. When one edge of the fabric encounters friction, it will be slowed down a little. This again will generate a cross direction force in the fabric, moving it toward the side with more friction. Please note that this applies for all items contacting the fabric; therefore a misaligned suction box can cause tremendous guiding problems too! There are several ways to increase the friction on the guide roll:
• Increasing the fabric tension; • Increasing the angle of wrap on the guide roll; • Increasing the diameter of the guide roll (thereby increasing the contact area); • Increasing roll softness. Water reduces friction Apart from the 4 points mentioned above, another critical consideration in maintaining friction is the amount of water on and around the guide roll. Water acts as a lubricant and when it becomes trapped between the roll and the fabric it drastically reduces the guide system’s effectiveness. Since fabric showering is critical to the total paper making operation, showering changes are normally used as a last resort to improve fabric guiding.
Figure 2
machines can contribute to guiding problems. When the guide roll is adjacent to the stretch roll, either on the ingoing or outgoing side, the wrap angle will change when the stretch roll moves. When a relatively short fabric is installed, as in the example in figure 3, the wrap angle will decrease and hence guiding problems may occur. Ideally the guide roll is positioned between two stationary rolls.
Wire tension As mentioned before, guiding is directly controlled by surface friction between the fabric and the guide roll. Surface friction in its turn is strongly affected by the fabric tension; the higher the fabric tension, the more surface friction and hence a more responsive guiding system. If experiencing guiding problems, always check for the correct operation tension on your fabric. Check the tension on both sides of the machine (TS and DS) and at the same position, for example before the guiding roll. Tension differences between the two sides are usually related to either misalignments or the forming fabric itself, but should always be resolved.
Angle of wrap around the guide roll The larger the angle of wrap around the guide roll, the higher the effectiveness of the guiding system. The minimum wrap angle varies a bit with the length of the fabric. For longer fabrics, like on Fourdrinier machines, a wrap angle of at least 25° (figure 2) is needed to adequately guide a fabric. For shorter fabrics, like top formers or gap formers, it can also be a little less to avoid a hyper-sensitive control system. Location of the guide roll in the machine The location of the guide roll on some (older)
Figure 3
Guiding roll cover Roll cover material and its hardness are critical in maintaining adequate friction between fabric and guide roll. Rubber-covered rolls with a hardness of 20 P&J are recommended for guiding today’s fabrics. However, because rubber rolls tend to harden over time, which reduces the friction between guide roll and fabric, periodic roll grinds are necessary to maintain the correct roll hardness. These rolls typically need to be reground every 2-3 years.
Polyamide yarns in the fabric In a forming fabric, the yarns in cross machine direction are usually made of polyester and/or polyamide. Polyamide is more wear resistant and helps to increase the fabric life. However, the friction coefficient between polyamide and the guiding roll is about 30% less than with polyester yarns. This means that the previous papermiddleast 33
remarks on tension, wrap angle and roll cover are even more important for forming fabrics with high polyamide content.
slotted ones. This will not only reduce the guiding problem, but it will also reduce fabric wear and improve the dewatering capacity of the suction box.
Drill and twill patterns Sometimes a guiding situation occurs where the fabric guides one way with the stock off and in the other direction when the stock is on. This situation is normally caused by one of two possibilities. Misalignment of a vacuum element A misaligned vacuum element will cause the fabric to guide, with the stock off, towards its leading edge. When the stock is applied and the vacuum becomes effective, the fabric tends to guide in the other direction. This usually requires a severe and fast adjustment by the guiding system to keep the fabric running properly. Always check for proper alignment of especially the vacuum elements when this phenomenon occurs. Drilled suction box covers If there is no misalignment and the machine has suction boxes with drilled covers, then the latter in combination with the fabric design may cause the guiding problems. There is a twill pattern in every woven cloth: it is actually the diagonal pattern caused by the cross-over points in the weaving process. When this fabric twill pattern and the suction box drill pattern match, the fabric will have a tendency, when vacuum is applied, to guide in that direction (figure 4).
Figure 4
To eliminate the possibility, the best option is to replace the drilled suction box covers with 34 papermiddleast
If replacing the covers is not possible, the second best option is to alternate the drill pattern angle in successive suction boxes. The last suction box in running direction should have the drill angle opposite to the twill angle of the fabric.
Troubleshooting list for guiding problems
1. Check the guide roll mechanism 2. Check the function (and position) of the guide plate 3. Increase the wire tension 4. Shut off the flooded nip shower and … 5. … increase pressure of the needle showers 6. Close or reduce lubrication showers near the guiding roll 7. Check the suction box deckles, couch roll deckles and pick up roll deckles 8. Eliminate pumping of the wet box/vacufoil 9. Reduce power consumption 10. Check the shaking mechanism 11. Check the drill and twill pattern (at the last suction box) 12. Check the water treatment of the lubrication showers 13. During a stop: check the roll surface of the guide roll (20 P&J) 14. During a stop: check the alignment of all the elements touching the fabric
Events >> Paper Arabia 2015
Paper Arabia with more than 10,000 visitors From 14 to 16 September 2015
W
ith an increase of 25 % compared to last year’s edition, Paper Arabia 2015, the first-of-its-kind industry exhibition was held at the Dubai International Exhibition and Convention Centre between the 14th and the 16th of September of 2015; attracting more than 10,000 trade visitors; Al Fajer Management confirmed.
Paper Arabia was inaugurated by His Excellency Mr. Buti Saeed Al Ghandi, Chairman of the Board of Directors, Emirates Investment and Development PSC, UAE and Managing Director of Al Ghandi Group. Paper Arabia 2015 a key platform for traders and industry players to interact, included leading participants and global names from the paper, tissue, packaging and converting sectors, featuring 100 companies from 45 countries in its 8th edition. “The figures indicate that the paper industry is seeing remarkable growth in terms of production, export of machinery, import of products and total investments.” Lamyae Zafati, Exhibition Manager, Al Fajer Information and Services, organizers of Paper Arabia 2015 explained. Paper, tissue and converting industries key players showcased their latest products, techno36 papermiddleast
logies and solutions for the entire production chain, from pulp to manufacturing, distribution, and wholesales/retailing; from trading to marketing, targeting paper mills along with a range of household paper for end users, and that during the three days of the show. “The show in its eighth edition attracted elite players from the paper, tissue and converting industry. It offered opportunities for manufacturers, suppliers and traders of finished products, equipment, machinery, paper chemicals, services, supplies of paper, tissue and converting sector to access the Middle East, North Africa as well as Asian markets.” Zafati explained. Paper Arabia also served as a launching pad for new technologies targeted at the Middle East region, and promoted technique improvement and economic development of the industry, and accelerated the modernization drive in this fast growing industry. The exhibition placed special emphasis on hygiene and disposable products, reflecting the demand for various products such as wet wipes, baby diapers and sanitary napkins. Since its previous edition, Paper Arabia has brought corrugated and carton industries on board due to the growing importance of these two dynamic sectors in the UAE and the Arab world. Highlighting the importance of Paper Arabia for the paper, board and pulp sectors, Zafati clari-
fied that Paper is replacing glass and plastics in packaging consumables products. This reflects the potential that the paper industry holds for the region as it serves as an alternative to other packaging options, including rigid plastics, flexible plastics, metal, glass and others for lower environmental impact, as well as the recycling trend that is gaining momentum in the Middle East, especially in the UAE. It’s worth noting that Paper Arabia 2015 comes at a time the paper industry is registering spectacular growth with several production centers and paper converting businesses flourishing. Manufacturers, converters, distributors, traders and decision makers from all over the world visited Paper Arabia to grow business and share expertise. “We have noticed so many family businesses engaged in the paper industry present at the show today, which has long history that goes back to 100 years. The show has attracted the full spectrum of the paper companies covering all the processes of producing paper from the very initial process of planting trees. The UAE is now a significant producer of paper, and a chunk of what it produces is exported to neighboring countries.” said Al Ghandi. Attracting key players in paper and tissues production, in addition to manufacturers of paper remittances from the Middle East and the world, the exhibition provided also an opportunity for major machinery manufacturing firms and other service providers to showcase their latest innovations with participation from, China, Czech Republic, Egypt, Libya, Finland, France, Germany, Hong Kong, India, Italy, Japan, Jordan, Saudi Arabia, Lebanon, Malaysia, Norway, Pakistan, Taiwan, Netherlands, UK, the USA, also from the UAE. It’s worth mentioning that the UAE is playing a key role in re-exporting paper and tissues to the entire MENA region. It is also a producer of paper with more than 12 mills based in the country; with Abu Dhabi based paper producers, Abu Dhabi National Paper Mill (ADNPM) and Queenex Hygiene Paper Manufacturing LLC (QHPM), being the two main participants at the three day show. Sponsored by Saudi Paper Group (SPG), the 8th edition of Paper Arabia 2015 has succeeded in
contributing effectively to the development of the paper, printing and packaging industry in the GCC. “The show reflected our efforts in highlighting key regional industry segments which have been contributing to the economic growth,” Zafati concluded.
On the other hand, Gulf based paper mills participating in Paper Arabia 2015 have called for establishing a new industry body to boost the Gulf paper industry and increase business volumes between Gulf markets as well as enhance collaboration in deciding pricing and distribution to external markets. Experts showed that paper could be a major contributor to boosting the industrial sector in the Gulf and support the Gulf countries’ drive towards growing non-oil economies. Furthermore, the Gulf paper industry has seen major developments over the past few years and with the exponential rise in its growth potential, leading local and regional players are now in the midst of strategic investment and market expansion as reflected throughout the three days of Paper Arabia 2015. It has been confirmed that Newsprint represents 12 percent of consumption of the overall general commodity paper in the UAE. The Newsprint paper includes newspapers and magazines, whereas general commodity paper includes office paper, notebooks, business cards, books, wedding cards, greeting cards and corporate and marketing collateral… “The paper industry market is growing tremendously, year on year, and new products are being launched on a regular basis. New companies are launching business in this field. Soft packaging is seeing high demand. Corrugated paper is being used for new patterns. Tissue paper is being recycled. Green campaigns are running in most of the countries.” Zafati concluded. papermiddleast 37
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