Pulp, Paper & Logistics March/April 2022

VOLUME 12 NUMBER 71

MARCH/APRIL 2022

LOGISTICS: Fast and flexible roll handling Pages 8-9

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INDUSTRY NEWS IN THIS ISSUE IN THIS ISSUE

Pulp Paper & Logistics

COMMENT

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elcome to the March-April issue of Pulp, Paper and Logistics, which arrives at a sombre time.

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INDUSTRY NEWS

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LOGISTICS

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Few of us could have missed being affected by the

callous attacks on Ukraine and its people. The world

has changed dramatically since our last issue. Refugees are spilling across Europe and global industries such as ours struggle to cope with the effects of volatile markets.

Fast and flexible roll handling

Our hearts go out to the displaced people, whether from Ukraine or Russia, all of whom need help.

On a personal level, I have been in occasional contact with a friend in Ukraine who I have known for more than 30 years. Recent

VALMET

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HEIMBACH

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A huge leap into a carbonneutral future

communications have been a bit haphazard so when I don’t get news for me it’s a big worry. On 21 March I had word that she is enduring bombings both day and night and spends most of her time in the shelters but somehow still manages to help other displaced women and

Welcome to the digital world

children with both food and clothes.

Sanctions on Russian oligarchs, whether political or commercial, have already had an effect on our readers in the pulp and paper industry; not just on those who are targeting weapons on people’s homes and places

ANDRITZ

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VALMET

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PRODUCTS & SERVICES

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PROJECTS & CONTRACTS

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PEOPLE

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Technologies to reduce carbon emissions in tissue production

of sanctuary. In response to this need, you can support the women and children through the websites of the many suppliers to our industry.

Please check locally.

Rebuilding for added value

One of the many long-term effects of the war in Ukraine is spiralling global energy prices. For those who rely on the market grid for energy are having to operate as leanly as possible, but for those who have onsite energy sources there will be less of an impact.

But the rise of commodity prices in parallel is bound to have a lasting impact on the industry as a whole. If we thought that the Covid pandemic was bad, then this man-made crisis is much worse, with a possible outcome that does not bear considering.

That is out of our control, so let’s support those who are suffering as best we can. Stay safe wherever you may be.

Vince Maynard, publisher

Vol. 12 Issue No. 71, March/April 2022 ISSN 2045-8622 (PRINT) PUBLISHER & EDITORIAL DIRECTOR Vince Maynard Tralee, Hillcrest Road, Edenbridge, Kent, TN8 6JS, UK Tel: +44 (0) 1732 505724 Mobile: +44 (0) 7747 002286 Email: pulppaperlogistics@virginmedia.com CONSULTANT EDITOR David Young Tel: +44 (0) 1737 551687 Mobile: +44 (0) 7785 796826

EDITOR John Nutting Email: johnnutting47@gmail.com REGIONAL REPRESENTATIVE Einar Johansson Tel: +46 8 540 255 15 Mobile: 0046 70 234 80 85 Email: einar.lennart@gmail.com

PRINTER Brown Knight and Truscott Tunbridge Wells, Kent, TN2 3BW United Kingdom Tel: +44 (0)1892 511678

PRODUCTION Anthony Wiffen ASTAC Business Publishing Ltd Tel: +44 (0) 1460 261011 Mobile: +44 (0) 7557 280 769 Email: anton_print_1@mac.com March/April 2022

2 INDUSTRY NEWS THE INDUSTRY VIEW

Consumers are changing how they consume paper and board The latest report from Cepi, the Confederation of European Paper Industries, shows how patterns are being disrupted across the news media, e-commerce and hygiene sectors Like other sectors, paper and board is bouncing back from the economic downturn brought about by Covid-19. But changes in how we use these materials, first exacerbated by the pandemic, are now looking more profound in consumption patterns. This has caused the industry to adjust its production, discontinuing lines and investing to adapt to the change. That’s the story told by preliminary statistics for the past year, published by the in-house statistics team at Cepi.

While consumption of paper products had slipped by 6.6 per cent in 2020, the sector is now showing signs of a strong recovery, with consumption increasing by 5 per cent over the past year in countries represented by Cepi. Exports outside of Cepi countries, which had declined by 8.4 per cent in 2020, are back to their 2019 level, driven by strong sales in the Americas.

Other factors are coming into play. On-line shopping was prompted by the pandemic, which has been a boon for producers of paper and board packaging with their output estimated to have increased by 7.1 per cent in 2021 compared to 2020, and up from a 2.1 per cent increase in 2019.

Combined with this is a new demand for our products’ encasings to be more sustainable, and the high recyclability of paper and board have contributed to the materials’ popularity amongst consumeroriented shippers and transporters, notably as a solution for the delivery of food or medical and pharmaceutical supplies. Paper is also a staple for the hygiene industry and, while demand for paper for sanitary uses decreased in 2021, it is still slightly above pre-pandemic consumption levels.

Pulp Paper & Logistics

Cost inflation affects sales at Smurfit Kappa

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murfit Kappa reported strong growth for the 2021 year, with sales up 18 per cent to €10.1 billion and profit before tax up 22 per cent to €1.7bn.

“2021 was characterised by significant and unprecedented cost inflation,” said chief executive Tony Smurfit. “These costs, particularly in energy, recovered fibre and other categories of raw materials, remain at elevated levels. We expect to continue to recover these costs, with margin improvement, as we progress through 2022.

“Driven by a number of longterm secular trends, we are reporting corrugated growth of 8 per cent. This growth is

a clear indication that paperbased packaging, renewable, recyclable and biodegradable, is the choice of our customers and the end consumer versus less sustainable alternatives.

“In early October, we completed the acquisition of a recycled containerboard mill in Italy with a capacity of 600,000 tonnes. This acquisition provides additional security of supply to our customers. In our Americas region, we continued our geographic expansion through acquisitions in Mexico and Peru. Our continuing, customer-led investment in converting assets, the most significant within the industry, together with our Verzuolo mill, will sustain a clear competitive advantage for Smurfit Kappa.”

The production of ‘graphic grades’, paper used for printing, drawing and writing, increased slightly, confirming the resilience of some sub-sectors in the midst of a structural decline. Another new reality is the continuing decline in demand for newsprint, with producers still adjusting to this.

The research, relating to both traditional and more innovative products from biorefineries, points towards what is known in the industry as the ‘substitution effect’. Paper and other forest-based products are set to progressively replace, to some extent, various less sustainable materials and chemicals. This is something the pulp and paper industry has pledged to support. Although these products still represent a marginal share of the overall production, Cepi statistics show that these changes are taking place rapidly and are even accelerating.

March/April 2022

Corrugated products grew by 8 per cent at Smurfit Kappa last year

INDUSTRY NEWS 3

Pulp Paper & Logistics

Billion euro investment at Oulo mill being considered

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urther investment of up to €1 billion to is being considered by Stora Enso at its Oulo mill in northern Finland.

This follows the conversion of the mill to produce containerboard, which was completed last year (as reported in PPL 70).

A feasibility study has been started for the possible conversion of an idle paper

machine at the Oulo site to a high-volume consumer board line.

A decision could be made by the end of this year with start-up in 2025.

Hannu Kasurinen, executive vice president at the Packaging Materials division of Stora Enso, said: “This investment would respond to the strong customer demand to replace plastic in packaging. During the study, we will evaluate the profitability of

the possible conversion and how to optimise current production synergies to create a modern mega-site at Oulu.”

The investment is expected to increase Stora Enso’s sales by €800 million a year. Wood pulp consumption at Oulo would be increased by about one million cubic metres, while an estimated 150-200 new employees would be needed, including logistics and maintenance. The investment

Stora Enso’s Oulo mill in Finland, where more investment is planned would also utilise captive chemical pulp, creating a net reduction of approximately 300,000 tonnes in Stora Enso’s total market pulp exposure.

The annual capacity of the converted machine would be 750,000 tonnes of folding box board, coated unbleached kraft and liner grades.

New speed standards set for containerboard production The PM10 line at Laakirchen Papier AG, part of Austria’s Heinzel Group, is reportedly the world’s fastest converted containerboard production machine with speeds of up to 1,450 metres per minute at a basis weight ranging from 70 to 140 g/sqm.

The machine had been rebuilt

by Andritz and in the process converted from production of SC paper to fluting and testliner. The project included the stock preparation section, a comprehensive rebuild of the paper machine, and complete automation.

Just ten weeks were scheduled for the conversion during which

the mill’s PM11 line continued operating. The PM10 produced saleable containerboard from the first reel.

Jan Reibert, production manager for the PM10, explains: “As of today, the PM10 produces premium quality lightweight containerboard at record speeds. And we still have an

ace up our sleeve: there is still potential for further increases in performance. The next step is for Andritz to upgrade the ropeless tail threading system in the double-tier part of the afterdryer section to reduce machine downtime and threading times compared to the market standard.”

March/April 2022

4 INDUSTRY NEWS

Pulp Paper & Logistics

Work starts at the $500m Pratt Industries mills in Kentucky

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onstruction has started on the Pratt Industries paper and corrugated box mills at Henderson in Kentucky.

The US$500 million investment in the US will create more than 300 jobs in the two facilities when production starts in 2023.

At the ground breaking ceremony, Anthony Pratt, executive chairman of Pratt Industries, commented: “Our Henderson paper mill and box factory is the single biggest investment our company has ever made and will create 1,000 jobs, including American, green-collar manufacturing and construction jobs.”

The ceremony came soon after a tornado had hit the state. “Our thoughts and prayers are with the people of western Kentucky at this

The ground breaking ceremony at the site of Pratt Industries’ mill in Kentucky difficult time and in support of those communities, I’m honoured to pledge $1 million to assist with tornado relief and recovery efforts in Kentucky,” said Pratt.

Georgia-based Pratt Industries produces lightweight, high-strength containerboard and corrugated board sourced from 100 per cent recycled paper. The company’s operations include paper mills in Georgia, Indiana, Louisiana, New

York and Ohio. Pratt Industries was established more than 30 years ago and employs more than 10,000 people in nearly 30 states.

Among the suppliers of equipment to the project is AFT, part of the Japanese Aikawa Group, which will be delivering stock preparation equipment for use on the PM18 board machine. The line will use 100 per cent recycled paper to produce corrugating

medium and linerboard grades.

AFT’s POMix units will deliver uniform top- and bottom-ply stock distribution to the machine headbox. The POMix stock processor is a patented, compact mixing design that replaces conventional large mixing chests and machine chests. Its small volume is said by AFT to provide a highly responsive and stable operation – an efficient ‘just-intime’ approach to feeding the paper machine that minimizes grade change time and off-grade paper.

“AFT is excited to be part of this project for one of the world’s most advanced, environmentallyfriendly recycled paper mills,” says Sven Girschner, regional manager for the Americas at AFT. “We are looking forward to a successful start-up in 2023.”

Worker dies after fall International Paper considers its position at SCA’s Ortviken mill with Russian JV

Police and the Swedish Work Environment Authority are investigating a serious workplace accident that occurred at SCA’s Ortviken mill at the end of January.

An employee working for a subcontractor of Valmet died after a fall at the flash dryer installation project.

Rickard Andersson, vice president of the Fiber Processing Business Unit at Valmet, commented: “Our thoughts are with the deceased’s family and colleagues. We have informed the personnel working with the March/April 2022

project on site and are giving them the needed support.

Investigation of the accident has been started and corrective actions will be implemented to continuously improve our processes and routines to ensure safety.”

Valmet said it is committed to protecting the health, safety and environment of its people, customers, partners and the communities where it operates.

Valmet has also initiated an incident investigation, in cooperation with the customer and contractor.

US paper giant International Paper (IP) is considering how it might pull its business out of Russia following the attack on Ukraine at the end of February.

On 11 March, IP announced in a statement that it would “explore strategic options, including the possible sale, of its 50 per cent ownership interest in Ilim Group” adding that it had no intention of suspending operations or starting liquidation or bankruptcy proceedings of the Russian jointventure.

Just over a week earlier at IP’s investor conference, chief executive

Mark Sutton alluded to the possibility of exiting from Russia.

In 2007, Memphis, Tennesseebased IP invested $650 million to create the joint-venture partnership with Ilim. Ilim is Russia’s largest forest products company operating three large pulp and paper mills with capacity for 3.6 million tons a year, and two corrugated box plants. IP’s partner is Russian oligarch Zakhar Smushkin. Chief executive is Ksenia Sosnina.

IP operates mills in North America, Latin America, North Africa and Europe with sales in 2021 of $19.4 billion.

Pulp Paper & Logistics

Move your performance forward at5 INDUSTRY NEWS Valmet Tissue Technology Center

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Valmet Tissue Technology Center provides a full sized, flexible pilot line to meet tissue makers’ every need and can be configured for production of plain, textured or structured tissue products or configured according to specific requests. The pilot line is equipped with latest technologies to ensure you can follow the trial on site or remotely. In close collaboration with you we can achieve great results!

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March/April 2022

6 INDUSTRY NEWS

Pulp Paper & Logistics

World’s first fibre-based paper tube lids to be launched

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candicore, one of the Nordic region’s leading manufacturers of fibrebased cores and tubes for the manufacturing industry, has launched what is claims are the world’s first paper tube lids.

In a collaboration with PulPac, it is producing paper lids made using Dry Molded Fiber technology.

One of Europe’s leading online stores for art prints will be first to

offer its products in completely plastic-free and fibre-based packaging supplied by Scandicore, which is based at Borås in Sweden.

Eva Engström, chief executive at Scandicore, commented: “Safeguarding the environment and the quality of our products, are our primary competitive advantages. The physical strength of the Dry Molded Fiber products, in combination with resource

All-fibre packaging tubes and lids are being marketed by Scandicore

Cepi members report paper and board up 5.8 per cent in 2021 Paper and board production in Europe reached 90.2 million tonnes in 2021, an increase of 5.8 per cent, showing a return to pre-Covid levels, reports Cepi, the Confederation of European Paper Industries.

Following a strong recovery of 5.3 per cent in 2021, the EU economy is now forecast to grow by 4.0 per cent in 2022 and by 2.8 per cent in 2023, says Cepi, although this was reported before the effects of the March/April 2022

attacks on Ukraine were understood.

“This rebound was also observed in most countries in the world.

China, the US, Japan, India, Korea and Canada recorded paper production growth ranging between 2 per cent and 7 per cent.

As a result, global paper and board production went up by around 3.0 per cent in 2021, according to first estimates, after the sharp decline recorded the year before of 5 per cent.”

efficiency, where valuable water resources and energy are saved, in addition to significant reductions of carbon dioxide, makes this a strategic investment for Scandicore.

“We have been listening to the market. This solution is heavily asked for by our customer and we are proud to start the journey to support the green and sustainable choice of our customer.”

Dry Molded Fiber, invented and owned by PulPac, is a fibre-

forming technology that can be used to replace single-use plastic caps with sustainable fibre-based alternatives at low cost. The patented technology is available to converters that have set up their own production. To accelerate the shift, PulPac has together with partners developed the PulPac Modula standardised machine platform, now starting to roll out to licensees and available at the PulPac Tech Center for sample and bridge volume production.

E-boiler will cut carbon emissions for Sappi Sappi is planning to modernise the steam generation boiler at its Maastricht Mill in the Netherlands as part of a longterm global commitment to sustainability and climate protection.

With an investment of almost €6 million, the paper maker says the mill’s carbon dioxide emissions will be cut by 22,000 tons a year, or by 13 per cent compared with 2019.

The reduction will be achieved by replacing part of the gas generated steam by electric generated steam using a new

e-boiler. The electricity used will be generated through renewable sources such as solar power and wind energy.

“The e-boiler project represents a key milestone in our plans to future-proof the Maastricht Mill,” says mill director Ferdinand Koster.

“The installation of the e-boiler will ensure a significant reduction in carbon dioxide emissions. And it brings us a clear step closer to achieving our sustainability targets for the mill by 2025 within the framework of Sappi’s decarbonisation roadmap.”

INDUSTRY NEWS 7

Pulp Paper & Logistics

Solenis joins the PulPac dry moulded fibre community

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leading producer of speciality chemicals, Solenis has joined PulPac’s worldwide network supporting the dry moulded fibre community.

Explaining the move, Daniel Palrén, business development manager at US-based Solenis, said: “We are excited to be a force for sustainable change in the packaging industry by contributing to this ground breaking technology.

“I believe we are uniquely positioned to provide safe and sustainable barrier solutions designed for circularity to the

Dry moulded fibre products are said to save significant amounts of water and energy and can have an up to 80 per cent lower carbon dioxide footprint compared to alternatives dry moulded fibre converters that lead the way and set new standards for fibre-based packaging.

“Fibre-based products coated with these barrier coatings

typically are repulpable, recyclable, compostable and biodegradable, thereby offering packaging producers a way to improve their sustainability credentials with brand owners,

retailers and consumers.”

Dry Molded Fiber, invented and patented by PulPac, is a fibreforming technology available to converters, brand owners and partners. It is designed to offer affordable, globally available, renewable cellulose fibres to produce high-performance, fibre-based packaging and single-use products with highly competitive unit economics.

Saving significant amounts of water resources and energy, a dry moulded fibre product can have up to 80 per cent lower carbon dioxide footprint compared to alternatives.

7–9 June 2022 HELSINKI, FINLAND

Welcome to the leading international event for the forest industry BUILDING TOMORROW’S BIOECONOMY

PulPaper is the forum for the latest technology and offers optimal business and networking opportunities in a multinational environment.

The global industry will once again be gathered in Helsinki.

For more information and contact details: pulpaper.fi #PulPaper2022

Exhibition • Conferences • Green Economy Business Summit • Excursions • Social events PULPAPER IS ORGANISED AT THE SAME TIME WITH the leading Nordic chemistry and biotechnology event ChemBio Finland and the international chemistry conference Helsinki Chemicals Forum.

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March/April 2022

8 LOGISTICS

Pulp Paper & Logistics

Fast and flexible roll handling As part of French paper maker Norske Skog’s conversion of a newsprint line to packaging board, Demag will be installing an automated paper roll store. PPL reports

P

aper maker Norske Skog has awarded a contract to Demag to design and implement a fully-automatic paper roll store at its Golbey mill in France, as part of the conversion project to produce more than half a million tonnes of recycled containerboard a year.

To carry out 160 roll movements per hour during March/April 2022

peak periods, the most effective method was with four automatic cranes, each of which having two hoists operating independently to ensure fast-and-flexible finished goods handling in a compact space.

With around 2,100 employees and yearly capacity for magazine paper of 2.1 million tonnes at five paper mills, the Norske Skog group is one of the world’s leading

paper manufacturers. At the Golbey mill, which is in the French Vosges region, up to 565,000 tonnes of newsprint is made each year on two lines, most of it from recycled paper.

One of the two lines, PM1, is being converted from making newsprint to recycled, lightweight packaging board with a capacity of 550,000 tonnes a year. As part of this change,

Norske Skog is setting up a new finished-goods automated store for this production line. Demag will plan and build the cranes for the store.

Rolls with a diameter of 1.40m will be stored in stacks up to a height of 15m at some 2,470 locations. The store layout is flexible, meaning that it can be adjusted to accommodate rolls with smaller and larger diameters.

LOGISTICS 9

Pulp Paper & Logistics

Demag is designing a fullyautomatic paper roll store for Norske Skog’s Golbey mill in France The store will feature space for a total of almost 15,000 rolls with a total weight of 41,400 tonnes when full.

To cater for future product variants, experience shows that the store will be operated at a capacity of 75 per cent, or about 31,000 tonnes. Since PM1 will have an annual capacity of 550,000 tonnes of recycled containerboard, this means that the warehouse will be replenished almost 18 times a year. The handling volume per hour is accordingly large: The forecast is that a maximum of 80 rolls will have to be stored and up to 140 rolls will have to be retrieved or re-arranged. On average, the actual numbers will be 32 and 104, respectively.

This entails demanding requirements regarding the automatic cranes’ capacity and

performance and will require a smooth and smart logistics process. As with all projects, this process will be developed together with the customer and the conveying equipment supplier and adjusted in line with future needs. From a warehouse management system perspective, the corresponding analyses and developments will include the entire material flow management from the winder, downstream of the paper machine to loading the finished products onto trucks.

For validation purposes, Demag recommended a material-flow simulation that considered both the storage area and the required crane performance, and the inbound and outbound materials handling equipment and the weights and dimensions of the paper rolls.

For PM1 in Golbey, Demag recommended four process cranes, each equipped with two hoists (each with a load capacity of 4.5 tonnes) that would be able

to travel independently of each other, as this arrangement would make it possible to handle very high transfer volumes at short notice.

Two double-girder overhead travelling cranes on a common runway with a span of 29.2 metres and a maximum lifting height of 18.5 metres will be installed in each bay. The key feature of these cranes will be a configuration with two travelling hoists that can move independently of each other.

This, combined with smart management by the warehouse management system, will be the key to the system’s high performance and flexibility. The winch units will not only be able to work in tandem and pick up or deposit two rolls (from either the same height or different heights), but also handle only a single roll and even take two rolls from a stack of rolls. Vacuum lifting units will be used to pick up loads gently.

Ultimately, the process cranes will take care of combined storage and retrieval operations while working automatically 24/7. The difference in quantity between the two types of operations is the result of the system working around the clock: in other words, filling the store while retrieval operations are performed only during the day.

Dr Thomas Bönker, Demag’s process cranes chief, said: “Many paper manufacturers are converting their plant production from printing paper to packaging paper and upgrading their storage systems in the process. With our process cranes and extensive engineering experience, we can design customised and highlyefficient material flow solutions for these needs.”

More information from Demag Cranes & Components GmbH, Ruhrstraße 28, 58300 Wetter (Ruhr), Germany. Contact Christoph Kreutzenbeck, tel: 02335 92 3907.

Warehouse truck battery collaboration The range of material handling systems offered by Yale Europe, including warehouse vehicles, has been enhanced with improved lithium-ion batteries supplied by Sunlight Group.

With 12 years of experience in research and development of lithium chemistry, Sunlight Li.ON FORCE batteries will be used in selected warehouse and electric counterbalance trucks.

The batteries are maintenancefree with long life cycles, says Yale. With no battery exchange required, Yale’s lithium-ionpowered products are said to offer more uptime as well as reduced running costs. The charging efficiency of lithium-ion batteries

is more than 90 per cent – greater than lead-acid options.

“Thanks to the success of our collaboration, Sunlight Group has become a trusted partner of Yale, helping us to deliver efficient and productive solutions for our customers,” said Marcus Rosenkranz, business director for Eastern Europe at Yale. “We’re excited for the next era of our working relationship, which will see Yale offer Sunlight Li.ON FORCE power solutions in our product line-up.”

Higher charging efficiency for lithium-ion batteries in Yale’s trucks

March/April 2022

10 VALMET

Pulp Paper & Logistics

A huge leap into a carbon-neutral future Biopower is key to the paper industry reaching carbon neutrality and simultaneously boosting the circular economy. Here PPL focuses on a new biopower plant at Laanila in Finland run by Oulun Energia and supplied by Valmet. Report by Marjaana Lehtinen. Images by Klaffi Tuotannot Oy

Targeting carbon neutrality. Pictured from left: from Valmet are Milena Rodriguez, product engineer, and Sami Ojala, product sales manager, and from Oulun Energia is Jukka Salovaara, project director

March/April 2022

VALMET 11

Pulp Paper & Logistics

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ocated at Laanila industrial park in the capital of northern Finland, Oulun Energia’s biopower plant started commercial operation in November 2020 and plays a vital role in the company’s goal of going carbon neutral. It also allows the growing energy demand in the region to be met. The plant sustainably produces 75MW of electricity and 175MWth of district heat, as well as process steam for nearby industrial sites.

Valmet delivered a multifuel boiler, flue gas treatment plant and plantwide automation system to Laanila. “The project went according to plan, thanks to Valmet’s experienced people, who always know what they’re doing,” says Jukka Salovaara, project director at Oulun Energia.

The feeling of successful cooperation is mutual. “It was

great to work with the customer’s professionals. They have extensive experience in the power plant sector. The project also included new technology, and the customer greatly contributed to its implementation with their views and experiences,” adds Harri Limo, project manager at Valmet.

Fossil fuels to be removed from the fuel mix The heart of the plant is a Valmet CFB Boiler, which uses circulating fluidised-bed technology (hence CFB) and is known for its high fuel flexibility. The boiler at Laanila runs mainly on biomass such as wood residuals, wood chips, sawdust and stump chips.

Other fuels include peat and solid recovered fuel (SRF) from Oulun Energia’s nearby Rusko wastesorting plant.

The boiler has a steamgenerating capacity of 194MWth at 120 bar and 540 deg C. It is 4

Oulun Energia’s biopower plant is equipped with Valmet’s advanced automation to control and support operations

Oulun Energia’s biopower plant started commercial operation in November 2020 and plays a vital role in the company’s goal of reaching carbon neutrality. It is equipped with Valmet’s advanced automation to control and support operations

March/April 2022

12 VALMET possible to increase or decrease the steam parameters, which further adds to flexibility if the fuel mix changes.

“Our fuel mix now consists of 70 per cent biomass, 15 per cent SRF and 15 per cent peat. In future, we plan to gradually stop using peat and increase the share of SRF to 30 per cent. We’re currently conducting a study with Valmet on utilising SRF more in our process,” says Salovaara.

Waste becomes an asset Oulun Energia’s drive for sustainability and the circular economy extends to the process’s side streams. For example, there is an ongoing development project with Valmet on the utilisation of ash. The aim is to study how

Pulp Paper & Logistics

to alter ash quality through combustion conditions, additives or post-treatment so that it can be used in forest or agricultural fertilisers or road construction.

What was once a cost may one day become an asset and a new source of revenue.

Flue gas cleaning is another example of the utilisation of something that was previously considered waste. Valmet’s flue gas cleaning system does a lot more than enabling the plant to fulfill stricter emission requirements. A flue gas condenser included in the system generates an additional 55 MWth of district heat, increasing the plant’s energy efficiency and district heating capacity. Even the water condensed from the flue gas

moisture is purified and used as makeup water for the boiler and district heating system.

Automation optimises production efficiency The entire plant is fully equipped with Valmet’s advanced automation to control and support operations.

Valmet delivered DNA automation, safety and information management systems, including applications for emission monitoring and power plant key performance indicator (KPI) calculations. The plant-wide automation system and Valmet Industrial Internet applications make it possible to optimise the use of the whole system in real time.

Valmet DNA automation enables the company to connect its Laanila plant with its Toppila power plant

and optimise its energy production efficiency.

Zero unscheduled shutdowns In addition to high energy efficiency, high availability and reliability were among Oulun Energia’s goals in making the investment. Valmet’s delivery checked the box.

“Since start-up, we’ve had no unscheduled shutdowns. The availability of both the boiler and the flue gas cleaning system has been very good,” concludes Jukka Salovaara.

More information from Jouni Kinni, senior sales manager, projects at Valmet. Tel: 358 40 0623610. Email: jouni.kinni@ valmet.com

The heart of the Oulun plant is a Valmet boiler which uses circulating fluidised bed technology and is known for its wide fuel flexibility March/April 2022

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14 HEIMBACH

Pulp Paper & Logistics

Welcome to the digital world As in most industries, artificial intelligence is key to improving decision making in the paper making business and its suppliers. Here’s how clothing specialist Heimbach has embraced it.

PPL reports

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rtificial intelligence has found its way into the operations of paper machine clothing specialist Heimbach, with tests into visual error avoidance paths and machine blogs having been running since 2020.

Since then, both the exchange of knowledge among employees and the transparency of production have been improved. Anomalies and sources of faults are clearly documented, and solutions are worked out in the team.

Now further improvements are being made to the structure of the digital process and digital training system.

Many areas of our daily lives have already been influenced by artificial intelligence for a considerable time.

This influence can be seen in our smart phones, social media feeds and online advertising. We are followed around the clock by clever algorithms.

In the paper industry, artificial intelligence is becoming increasingly important. The opportunities are everywhere,

The principal component analysis (PCA) shows coloured clusters with similar properties whether we are talking of process optimisation, relieving employees or cost reduction.

Visual error prevention paths and machine blogs How to optimise product quality through visual error prevention

paths and machine blogs? How to contribute to bringing even greater machine efficiencies to the customers? What are the possibilities opened up by the Internet of Things?

The aim of these considerations was to introduce systems

for root cause analysis and presentation and to anchor, as firmly as possible, the exchange of knowledge between experts on site. Heimbach has now been able to make great progress along this path and is currently in the process of transferring the positive results from machine blogs to the finishing department and ultimately to the needling department.

Digitisation of learning and production processes

Significant instances of machine downtime and start-up behaviour March/April 2022

The Industry 4.0 working group has been meeting regularly for some time to discuss and document the progress of different projects. With its own search engine, or training platform, knowledge exchange within the Heimbach Group has

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also become faster and better.

The prototype of a digital training system has been tested and evaluated by 45 employees.

Learning modules on the topics of occupational safety, hazardous substances, energy, paper machine clothing and corresponding explanatory videos were rated positively across the board: Good user-friendliness, high flexibility and instructive content. In addition, the attractive look and appealing user interface have significantly increased the joy of learning.

Based on this, the infrastructure for digital training will be further expanded. The first training tools for the areas of occupational safety and IT security were already implemented at the end of last year.

The programmes are automatically aligned with respective requirement profiles and can guarantee targeted learning. In turn, this means that the know-how imparted can be much more precisely adapted to specific needs within the company – and at the same time to those of Heimbach’s customers. And all of this within a much shorter time frame.

Transferred into production this means: Learn even better from the data, recognise correlations more clearly and make more precise predictions. Errors and the causes thereof, which were not able to be fathomed directly previously, can now be analysed.

Wolfgang Müller, foreman for base fabric manufacturing, checks the recorded operating data for correctness reproducibility, efficiency and strength?

Evaluating this and having the capability to reliably predict it is an extremely time-consuming task. That is without taking into account identifying individual outliers in the labyrinth of measurement profiles, curves and statistics. The aim is to reduce this huge flood of data to just 20 variables with the help of AI.

It is about much more than streamlined data, however. It is equally important to bring the expertise of employees into a digital format: to visualise the results within the framework of a team, discuss them and expand knowledge. Put into one sentence: striving for faster problem solving by means of shorter paths and more active participation within a digital

learning environment and structured processes.

At Heimbach, the benefits of AI extend far beyond laboratories and factory halls. With the new, more intelligent form of troubleshooting, the data provided can be evaluated in a more targeted way and at the same time requirements and difficulties can be reacted to more quickly.

Only 20 influencing variables instead of 350 In the course of the production processes at Heimbach, around 350 influencing variables have to be taken into account. How do changes in length and width affect our press felts? How are we to evaluate the wear processes? What statements can be made regarding

Frank Salge, base fabric manufacturing manager, always has an eye on the machine utilisation rates March/April 2022

16 ANDRITZ

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Technologies to reduce carbon emissions in tissue production Despite being energy intensive, pulp and paper mills are one of the least carbon-dioxide intensive industries because of their wide use of bio-based and renewable fuels. But the tissue and towel sector emits more carbon per tonne of paper than most other paper grades, primarily due to their use of electricity from fossil-fuel sources. Bob Puhr explains how Andritz is helping to reduce the carbon footprint for tissue production through its ‘CircleToZero’ initiative

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ulp and paper production plays an essential role in the economies of many countries. While there are industries that emit considerably more greenhouse gas (GHG) emissions than pulp and paper, the industry’s GHG output (estimated to be about 9 per cent globally) is large enough to attract the attention of governments and consumers.

The GHG most relevant to the paper industry is carbon dioxide (CO2), with smaller amounts of methane and nitrous oxide. These emissions are generally reported as mass of carbon dioxide equivalent (CO2eq).

Twelve countries account for 80 per cent of worldwide tissue and toweling production. Carbon emissions from the European Union’s (EU) paper industry have reduced by 48 per cent per tonne during the period from 1990 to 2019. The EU has defined a set of ambitious targets to limit

Andritz offers solutions to reduce carbon dioxide in tissue production the increase in average global temperatures. These include reducing GHG emissions by 40 per cent by 2030 and by 80-95 per cent before 2050 (compared to 1990 levels).

Specific energy consumption for tissue is highest of the standard grades, primarily due to the drying process. In a study

of US mills, tissue production was second highest in total GHG Intensity (behind speciality paper grades) at 1,720 kg of CO2eq per metric tonne of product from fuel, purchased electricity, fibre, chemicals, and transportation.

There are clearly opportunities and challenges for tissue and toweling producers with regards to reducing GHG emissions and strengthening the relationship with consumers who increasingly prefer carbon-neutral products.

Practical ways to reduce the carbon footprint of tissue

Carlos Gallo, product director for tissue and drying at Andritz March/April 2022

At a mill site, the actual production of tissue/toweling emits a relatively small amount of GHG, especially if the electricity and steam energy is derived from

non-fossil fuel sources. However, in addition to combustion of on-site fuels, the tissue industry is also measured on its use of indirect emissions of GHG due to off-site generation of heat, steam, and electricity that are purchased by or transferred to the mill.

Our challenge as a technology partner with the tissue industry is to not only offer solutions for conserving energy and raw materials within the mill complex – but also solutions that help mitigate or replace GHG emissions from ‘upstream’ sources of fibre, electricity, water and chemicals.

This work is part of the global ‘CircleToZero’ initiative at Andritz, an initiative to achieve zero emissions and zero waste. Emissions of all sorts

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Luca Linari, managing director of Andritz Novimpianti can be thought of as losses or waste. Recovering, reusing, and recirculating these potential losses offer clear environmental and financial benefits for customers.

Step-by-step to carbon footprint reduction Andritz’s observation, based on decades of personal experience serving tissue customers around the world, is that each mill site is unique. Sure, there are product solutions and technology modules that are building blocks for a lot of

machines and mills. But generally, these building blocks require Andritz’s design and engineering expertise, working closely with each mill, to achieve the best results.

Andritz offers solutions to reduce a tissue mill’s carbon footprint in energy, fibre, water, biochemicals, and digitalisation.

From its calculations (Figure 1) Andritz estimates that a typical tissue machine using conventional technologies (e.g. suction press rolls and cast Yankee) and

producing 200 t/d emits just over 47,000 tons per year of CO2eq.

This is for the stock preparation system and the machine itself, and not for other upstream or downstream processes.

Some of Andritz’s technology modules which reduce kW/t, and therefore CO2eq/t, are shown in Figure 2. Implementing these modules, each of which has its own ROI benefits, makes it possible to reduce kW/t by up to 17 per cent and CO2eq/t by about 15 per cent.

These are significant reductions.

The modules include: c Modifying the approach flow system (double dilution) to reduce the energy consumed by the fan pump and screen by about 10 per cent. c Insulating the heads of the Yankee to reduce energy losses and to reduce steam consumption by about 5 per cent. c Utilising vacuum blowers

instead of water ring pumps to save about 25 per cent energy in the main motors. The exhaust from the blowers is hot enough to be used in different heating systems and less fresh water is required to operate them. c Installing a Rebel highperformance roll cover (Figure 3) on the tissue suction roll can improve sheet dryness after the press of 1 per cent and more, allowing a machine speed increase or energy savings in the drying section between 50100 kWh/t of paper produced.

The Rebel can operate without water cooling, permitting energy savings up to 25 per cent of the initial roll driving power requirement. c Installing a PrimePress XT Evo shoe press (Figure 4) to reduce fibre consumption and/or save energy. The shoe press is loaded by two pressurised hoses, allowing a mill to fine-tune 4

Andritz offers a variety of practical systems to reduce a tissue mill’s carbon footprint by managing energy, fibre, biochemicals and automation March/April 2022

18 ANDRITZ the nip profile for maximum dryness, or maximum bulk, or somewhere in-between. If the goal is high dryness, the PrimePress XT Evo offers about a 6 per cent after-press dryness gain compared to a conventional suction roll – meaning thermal energy savings of up to 24 per cent. If the goal is high bulk at the target same dryness, basis weight or fibres can be reduced up to 10 per cent – reducing the corresponding CO2eq emissions. In combination with the PrimePress XT Evo shoe press, Andritz supplies shoe press belts and press felts to achieve maximum post-press consistency for the lowest possible energy consumption. c Installing a PrimeDry YES heat recovery steam generator system (Figure 5). This uses exhaust air from a gas-fired Yankee hood and condensate from the Yankee with a steam generator (heat exchanger) to produce 15 per cent of the steam required for the Yankee, saving up to 5 per cent in thermal energy consumption. c Installing a larger diameter PrimeDry Steel Yankee in combination with a steamheated PrimeDry Hood. Steam generated with biomass is used in both systems resulting in a drying system with zero CO2eq emissions. c Another possibility is to use biomass to generate renewable bio-syngas to replace fossil fuels when firing the Yankee burners. Sofidel, a major European tissue producer, entered into a long-term collaboration with Meva Energy to build and operate a syngas generation plant at Sofidel’s Kisa mill in Sweden, utilising biomass as the feedstock. This will enable the mill to reduce March/April 2022

Pulp Paper & Logistics

Figure 1: Typical energy consumption data for a dry-crepe tissue machine

Figure 2: Potential for energy-reduction with Andritz technologies CO2eq emissions by 8,500 t/a.

Andritz Novimpianti air and energy and Andritz burner experts are collaborating in the project, which also involves the Department of Energy of Pisa University c Some tissue producers are considering on-site cogeneration of electricity, especially when there are no fossil-free sources for purchased electricity.

Andritz offers the option to use hot air from the turbine exhaust to heat the Yankee hood, allowing conventional hood burners to be switched off (Figure 6). The hot exhaust air can also be used to generate steam for the Yankee. With cogeneration in place, a mill can be self-sufficient from an electrical view and may be able to sell excess kW to the grid to

generate revenue.

c Hydrogen (either purchased or produced on-site by means of

electrolysis) can replace natural gas and significantly reduce CO2eq emissions. Hydrogen

Figure 3: Rebel, a premium polyurethane cover for tissue pressure roll positions, delivers improved dewatering

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Figure 4: A PrimePress XT Evo shoe press can reduce fibre consumption and save energy can be used to replace 100 per cent of the fuel used to heat the Yankee hood while also partially replacing the fuel used in a cogeneration system.

Combustion of hydrogen provides a direct reduction of CO2eq and CO emissions by about 15 per cent.

For mills located in regions where CO2eq emissions are restricted, but there is increasing consumer interest in higher quality products, a new technology PrimeLineTEX machine may be worthy of consideration. The PrimeLineTEX produces a ‘textured’ sheet with quality much better than dry-crepe and close to TAD. The required energy is slightly higher than dry-crepe, but about one-half that of TAD. The higher quality of the TEX products, opens the possibility to substantially reduce (up to 30 per cent) the fibre input compared to dry-crepe.

While the reduction in water consumption is not directly related to CO2eq emissions reduction, the transport and treatment of water in a tissue mill requires energy and chemicals. Andritz has a portfolio of product solutions to close the water loop in the mill, as well as the ability to recover evaporated water from the Yankee/Hood systems and recirculate it for tissue production.

Current lab trials at the Andritz Tissue Innovation and Application Center (PrimeLineTIAC) in collaboration with a global leader in chemical supply are developing sustainable biochemicals for tissue production.

These bio-renewable products will contribute to overall carbon emission reductions.

Any tissue mill can benefit from digitalisation to improve efficiencies and repeatability.

Digital solutions such as Andritz Metris are well suited to optimise production while minimising a tissue mill’s total GHG emissions. Since there are very few integrated tissue mills

Figure 5: A PrimeDry YES heat recovery steam generator system existing today that have access to steam generated by non- fossil fuel sources such as black liquor or wood waste boilers. The Metris APC Tissue Energy Balance systems would be beneficial in minimising steam and electricity requirements. The result is less of a demand on the mill’s main steam requirements, allowing for a reduction in fossil fuel usage (and the corresponding reduction in GHG emissions).

Other Metris systems include advanced dryer controls to save considerable energy with excellent payback. Metris APC enhances the standard regulatory or DCSlevel controls found in typical mill and are specifically focused

on optimisation of throughput, quality, and cost. A major advantage to tissue producers is the use of integrated artificial intelligence (AI) and machine learning (ML) in these digital systems which can duplicate the decisions of the very best operators to avoid sheet breaks and other downtime. These systems also ‘remember’ startup and shutdown sequences to minimise waste or disruptions and can handle changing conditions and adjust accordingly.

Co-authors and interview partners: Carlos Gallo, Product Director, Tissue and Drying, Luca Linari, Managing Director, Andritz Novimpianti

Figure 6: Some tissue producers are considering on-site cogeneration of electricity, especially when there are no fossil-free sources for purchased electricity March/April 2022

20 VALMET

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Rebuilding for added value Pulp dryers can be adapted to every customer’s needs with Valmet’s range of conversions and upgrades using either the company’s module-based, or even third-party, systems. Kristofer Sjöblom and Hugh O’Brian explain. Photography by Lars Berggren and Hannes Frigård

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almet’s Airborne Dryer concept is module-based, and can be adapted for each customer and each dryer, whether the dryer is relatively new or old, large or small.

“We conduct many small and medium-sized rebuilds on existing pulp dryers, and we get many large assignments in which the entire dryer is essentially rebuilt from scratch,” says project manager Kari Koski. “Increasing production is the most common reason for such projects, but they can also be aimed at reducing dust formation or streamlining the workload for operators, for example. Wear and outdated technology are further reasons for

a dryer to be rebuilt.”

A typical rebuild may consist of replacing or adding blow boxes, fans and end towers to increase the drying capacity.

The conversion may also include upgrading to automatic tail threading to minimise downtime.

The dryer can also be upgraded

Valmet’s Booster Dryer offers modular design for flexibility in expansion projects

with smart technology that reduces dust formation and increases runnability.

“All rebuilds are quite different,” comments Koski. “For example, we might replace fans, steam coils and access hatches, or automate tail threading. A rebuild might also entail building new drying decks in the upper part to increase evaporation capacity or improve heat recovery. No matter what the issue is, we can make any dryer maximally competitive with the latest innovations.”

An important task for Valmet is to reduce customers’ investment and operating costs.

All conversions and upgrades are therefore tailored to keep the project’s total costs to a minimum,

while the technology added must provide the lowest possible operating costs.

Booster dryers – increased production by using a spaceefficiency There may be several reasons to rebuild a dryer, the most common being to increase production capacity. With Valmet’s Booster Dryers, pulp output can be increased with a targeted extension that is placed on top of, after or inside the existing dryer. The one that is selected will depend on a customer’s particular needs.

Adding a Booster Dryer extension on top of or after the dryer can be done on almost any pulp dryer. On the other hand, if customers want to add capacity inside the dryer, space must be reserved for this during the original planning when it is built. It is thus already prepared for a capacity increase, which is easy to do when needed.

An additional advantage with this is that there is no need to increase the dryer’s physical size or footprint. Because of the extreme flexibility it offers, and as each project is unique, there has been great interest in the Valmet Booster Dryer for expansions.

Rebuilding and upgrading of non-Valmet dryers

Kari Koski, project manager at Valmet March/April 2022

It isn’t just Valmet’s dryers that are being rebuilt and further developed.

“More and more assignments

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Valmet offers a number of booster dryers to increase production capacity

involve rebuilds of non-Valmet dryers. The mill wants to keep the dryer frame but upgrade it with selected parts from the Valmet Airborne Dryer technology. Customers are well acquainted with our expertise and technical innovation,” says Koski.

“Such an assignment is especially stimulating, because we have the confidence to develop a technical solution that is not originally our own. To do this, we start with a feasibility study in which we thoroughly analyze the existing dryer and then carefully develop our plan.

This lays the foundation for a successful end result.”

project management are therefore very important. Koski explains: “Careful planning and proactive project management are of great importance for the project to run smoothly and well. We have

extensive experience of carrying out renovations and planning the work to minimize downtime.”

But even if everything is prepared and planned in detail, the unexpected can happen.

“Regardless of whether it’s on a weekday, a Saturday evening or a holiday, we always act quickly. We earn our customers’ trust, and we ensure this trust is well managed,” concludes Koski.

When the unexpected happens A conversion project can be especially demanding when the work is carried out while the dryer is in operation. Planning and March/April 2022

22 PRODUCTS & SERVICES

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Energy efficient innovation for Crescent formers

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o improve energy efficiency and working conditions in the wire section of Crescent Former tissue machines, Toscotec has launched its TT LowMistFormer.

Originally designed by Voith, the system has been integrated into Toscotec’s former design. The TT LowMistFormer technology has been included on a number of Ahead tissue machines manufactured by Toscotec.

Enrico Raffanti, Toscotec’s deputy chief technical officer, commented: “TT LowMistFormer improves the runnability of the machine in the key section of paper formation, leading to higher process stability.

“This new concept is perfectly in line with our mission as manufacturers of advanced

Mist is captured and carried away through the venturi effect generated by the jet speed in Toscotec’s TT LowMistFormer technology, developing innovative solutions to boost production efficiency while reducing energy consumption, in order to

increase sustainability in paper production.”

By creating a screened area in the wire section with

an optimised combination of fixed elements, the TT LowMistFormer is said to provide remarkable air, water, and mist flow performance. The mist is captured and carried away through the venturi effect generated by the jet speed of TT Headbox.

The system reduces mist in the environment and healthier conditions around the wire section, which normally produces the highest concentration of mist. There is also a significant reduction of dirt build-up on the machine, which reduces the need for cleaning and maintenance on the production line and in the building.

More information from Marco Dalle Piagge, sales director at Toscotec Tissue division. Email: marco.dallepiagge@toscotec.com

Predictive maintenance tool identifies ‘invisible’ sleeve damage Invisible damage to press sleeves resulting from web breaks and paper jams is easily identifiable with an addition to Voith’s QualiFlex range of products.

The QView press sleeve is designed to make internal damage visible and help papermakers take action before severe failures happen.

A predictive-maintenance product for board and packaging paper machines, QView has two novel features. Dyed lubricating oil and a specially-coloured polyurethane are used for the press sleeve. Any cracks in the March/April 2022

UV light identifies cracks in press sleeves when the QView press sleeve is used press sleeve absorb the dyed oil and, when exposed to UV light, a strong contrast between the intact area with no oil and the damage becomes visible.

Due to its special colour, the press sleeve allows the UV light to shine through and makes inspection as well as predictive maintenance easier. Hence,

QView functions as an early warning system and reduces unplanned paper machine shutdowns while increasing efficiency and saving costs.

“Not only does the QView press sleeve have an excellent running performance as well as good crack resistance, but it also helps to avoid oil leakage,” says Christina Bauer, global product manager, press section & QualiFlex at Voith Paper.

“Combined with the damage detection at an early stage, the QView press sleeve makes the customer’s life much easier and saves resources.”

PRODUCTS & SERVICES 23

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Better stock cleaning with energy savings

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o achieve optimised cleaning during stock preparation with energy savings, Voith has launched the InduraClean (IDC) product range as part of its BlueLine portfolio.

The system consists of an improved cleaner bank, which can be combined with both the new IDC-4 and optimised IDC-5.

Depending on requirements, the focus of the modular cleaning technology can be on increased production, energy reduction of up to 50 per cent or improved separation efficiency.

“We have already received very good customer feedback: the cleaner installations are running efficiently and smoothly,” says Stefan Walker, area sales manager at Voith Paper. “A quick start-up was ensured by our experts. The results are very satisfying. With the help of the new cleaners, our customers can significantly reduce their energy requirements and minimise fibre losses.”

The IDC-4 combines four

“The InduraClean IDC-4 has already proven its operational reliability, ease of maintenance and high separation efficiency in a wide variety of installations,” says Thomas Jaschek, global product manager at Voith Paper individual high-efficiency cleaners to provide high throughput in less space. The cleaner bank features a flow-optimised design that avoids deposits due to rejects or heavily-loaded grades. Besides the revision of the cleaner connection, the bank has been extended to include individual isolation. This means that individual cleaners can now be

shut down during operation as needed.

“We can offer individual solutions for all customer requirements,” says Thomas Jaschek, global product manager at Voith Paper. “The InduraClean IDC-4 has already proven its operational reliability, ease of maintenance and high separation efficiency in a wide variety of

installations. Customer reactions to the results and operation have been consistently positive. Even at low pressure differentials, the extremely robust cleaners achieve high separation rates. This allows new circuit concepts and thus high energy savings.”

There are two versions of the InduraClean IDC-4, depending on the application. The IDC-4F (FourFlow) is designed for higher production capacities, especially for board and packaging papers.

The IDC-4Q (FourQuality) is suitable for speciality and graphic paper grades, as here the focus is on very high cleaning efficiency and quality. The new product family also includes the widely used cleaner type HCL 5 – now referred to as InduraClean IDC-5.

Unlike the InduraClean IDC-4, it contains just one cleaner cone.

In addition to the installation of the new cleaner banks, Voith also offers the fast rebuild of existing banks.

More information from www. voith.com/cleaning

Giving new life to tissue embossing rolls Two new services for tissue manufacturers that give new life to embossing rolls have been launched by Engraving Solutions, a Körber Group company.

The Italy-based firm, which specialises in designing and

engraving embossing rolls, has designed the products to meet demand for products with a low environmental impact.

The two services are called Buy-Back and Rised and are complementary: the first is a

Cost savings in embossing rolls are offered with the new services offered by Engraving Solutions

buy-back service, conceived after evaluation of unused embossing rollers by the Körber purchasing department. The engraved pattern on the roller is destroyed and the surface regenerated to be used again.

With Rised, a new roller is made by starting from the one regenerated. The result is a product with the same performance as the new one, but at a lower cost.

Giacomo Tambellini, sales account and product engineer, comments: “For some time we have observed that our customers

have two major needs: on the one hand they need solutions that limit the waste of energy and raw materials, and on the other hand they are concerned with cost saving. With the two new Buy-Back and Rised services, we believe we have responded to both requirements.”

Tambellini concludes: “This is a truly circular economy: thanks to the buy-back service, unused rollers are recycled, while with Rised products are created as new, safeguarding the environment by reducing the emissions necessary to build new ones.”

March/April 2022

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Wider range of tissue folding options from Körber

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complete range of interfolded tissue products is possible with a new machine launched by Körber Business Area Tissue, which is based at Lucca in Italy and is part of the Körber Group.

The MTC ITF omni taquera is said to be capable of folding facial products, towels, folded toilet paper, and even taco napkins with a dispenser.

Stefano Anelli, Körber Tissue’s sales manager, comments: “The South American market needed to have a napkin specifically designed for wrapping tacos. From this need and from the collaboration between the sales office, research & development, and specialised

Said to be ideal for companies that work with diversified clientele, the taquera option can be integrated on all Körber Tissue MTC ITF omni lines technicians, the MTC ITF omni taquera was born, an extremely versatile solution that can be installed on the MTC ITF omni lines that allows it to produce all the interfolded products, including

the napkins for tacos, with a single bending head.”

The MTC ITF omni taquera, combined with automatic packaging of napkins in a portable dispenser with serial extraction,

enables customers to preserve the hygiene and safety of the finished product while avoiding contamination of the wipes.

Anelli concludes: “Thanks to the MTC ITF omni taquera, Körber Business Area Tissue confirms its role as a company that is attentive to offering its customers cuttingedge and innovative solutions.

The know-how acquired over the years in the fold sector and the continuous desire to create highly performing products has allowed the company to develop a competitive product with high growth margins. The solution created for the South American market, in fact can be used in different sectors with similar product needs.”

Plant-based dyes for paper create value from waste A coloured paper range using dye derived from plant extract that would have otherwise been wasted has been launched by UK-based James Cropper. The new Wainwright Colours from Nature range is the papermaker’s latest in a list of innovations that create value from waste streams.

Joanne Storey, R&D programme lead at James Cropper, said: “It’s the first-time plant-based dyes have been used in modern papermaking: a breakthrough which marks the first step into the development of more natural colour options. We are investigating botanical dyes extracted from a wide variety of origins including plants, shells and fungi; and expect the range to expand significantly.”

The first two shades, Limestone March/April 2022

and Herdwick Brown, are both derived from rosemary residue, a waste stream in some food production. The rosemary is grown as an annual agricultural crop before the non-edible waste from the plant is extracted and upcycled into the dye, which is added to James Cropper’s 100 per cent FSC recycled paper.

Designed primarily for the packaging and publishing sectors, extensive research and development work has ensured that the Wainwright Colours from Nature collection offers a bleedfree, rub resistant dye which has lightfastness similar to that achieved using industry standard synthetic dyes.

The colours were created to celebrate James Cropper’s partnership with The Wainwright

James Cropper’s latest coloured paper range uses a bleedfree, rub resistant dye which has lightfastness similar to that achieved using industry-standard synthetic dyes Prize, an annual literary award for the best UK-based nature and global conservation writing. The colours are inspired by author Alfred Wainwright’s love for the

Lake District landscape and James Cropper’s desire to protect it.

More information from www. jamescropper.com/wainwrightcoloursfromnature

Tel: +353 (0) 86 0440956 Fax: +353(0) 69 85927 Email: sales@biomass.ie www.biomass.ie

26 PROJECTS & CONTRACTS

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Optimising remotely improves grade changes at Hamburger Containerboard

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rade change improvements by 35 per cent, optimised length profile and more stable processes have been achieved on the PM1 line at Hamburger Containerboard’s Spremberg mill in Germany after remote work by experts from Voith’s OnPerformance.Lab (OPL).

With capacity of 340,000 tons a year, the line makes white uncoated and coated papers as well as gypsum board with basis weights between 120 and 180 gsm.

To increase the efficiency of the line and to optimise product quality, Hamburger Containerboard, a member of the Prinzhorn Group, has been working with the OPL experts for more than a year.

The remote optimisation began with the collection of process

Voith’s OPL experts suggested changes in Hamburger Containerboard’s PM1 to improve performance and machine data from PM1, which Voith used to find ways of increasing the efficiency of the line. OPL experts then discussed the issues occurring on the machine with all project participants, refined the models,

adjusted controller settings and suggested program changes in the customer control system. In regular feedback meetings, the teams evaluated each step and made joint decisions on how to proceed.

Remote commissioning at ITC’s Tribeni mill in India The installation and remote commissioning of a new profiler system and a new actuator for slice lip weight control has been completed by ABB at the Tribeni mill of ITC Paperboards and Specialty Papers in West Bengal, India.

The project, managed by the specialist Quality Control Systems (QCS) team at ABB India, included the replacement of ABB’s existing cross-direction (CD) weight control system (Slice Profiler) with the latest Slice xP (II) Profiler under a product phase March/April 2022

out notification. The Slice xP (II) is ABB’s latest actuator technology for slice lip weight control head boxes and falls within the weight extended profiling (xP) family designed to meet exacting specifications that exceed process requirements.

As a result of the upgrade to Slice xP, which is said to be easy to install and maintain, ITC will benefit from reduced CD profile variability and advanced diagnostics through the built-in monitoring of each actuator.

Its high-speed, non-contact

positioning sensors are said to ensure precision even after a power loss. This enables mills to achieve a fast recovery from grade changes and process upsets.

ITC’s Tribeni mill has produced a diverse range of industrial and fine papers for more than 50 years, with capacity for 50,000 tons per year. As well as having all relevant ISO accreditations for quality management, environmental standards and health and safety, ITC is Forest Stewardship Council - Chain of Custody certified; it uses

David Wötzel, QCS automation engineer at Hamburger Rieger GmbH, said: “Thanks to their comprehensive expertise and holistic approach, the OPL experts defined individual and reliable recommendations that stabilised our process and ultimately led to a significantly shorter grade change time.

“The cooperation was simple, flexible and smooth throughout the entire period. Just like with a colleague – only from a distance.

It was essential for us that the optimisation measures did not disrupt the daily routine or processes in the plant. We were able to implement them whenever they fit into our schedule. You can simply tell that OnPerformance.Lab is staffed by experts who know how complex the papermaking process is and which solution approaches are individually suitable.” responsibly-produced raw materials including timber sourced from sustainably managed forests.

“The move from a phase out product to a new product not only improves our reliability and achieves higher maintenance, but it also reduces our risk of breakdown and therefore inventory costs,” said Biplab Bhattacharya, head of electrical & instrumentation at ITC Paperboards and Specialty Papers.

“ABB’s well-considered lifecycle policy enabled us to be proactive with our upgrade strategy. The team’s ability to deliver remotely was critical in achieving our modernisation goals to schedule.”

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Drying, air and energy technology for Essity in the US

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rying, air and energy technology is being supplied by Andritz to Essity’s professional hygiene business for use on its PM3 and PM4 tissue machines at the Menasha mill in Wisconsin, USA. With start-up expected for the end of 2022, the equipment is said will enable sustainable and resource-saving production.

It includes a PrimeDry Hood HT (high-temperature) and air systems for the PM3. Similar hoods were recently started on the PM4 and PM15 lines.

Also included is an 18 feet PrimeDry Steel Yankee for PM4, with head insulation for energy efficiency and Andritz’s own metallisation – PrimeCoat Stratos – to provide greater hardness and extended life.

The drying equipment will enable the tissue machines at the Menasha mill to operate at speeds of up to 2,000 m/min and for a wide range of basis weights.

Mark Phiscator, engineering service director at Essity North America, explains: “Our ambition is clear: We aim to innovate and implement new and improved production solutions with a smaller environmental footprint.

And we expect the same from our suppliers. This is why we chose to work with Andritz for the upgrade of our two tissue machines. We’ve worked together with the Andritz tissue team in Montreal for a long time and really appreciate their expertise.”

Essity is a leading global hygiene and health company with sales in around 150 countries, selling products under the Tork brand.

Quality control system for Papeterie Le Bourray in France

Key rewinding components for PT Mega Surya Eratama

An IQ Quality Control System is being supplied by Valmet to Papeterie Le Bourray in France.

The new system will replace an aging third-party system and will be installed on tissue machine TM3 at the company’s mill in Saint-Mars-La-Brière, in northwest France.

With delivery expected in November 2022, the IQ Quality Control System will be supplied with scanner, related systems including online colour measurement and quality controls. With more accurate data available and state-of-the-art multivariable control technology, the machine can be controlled much better than before, resulting in improved machine performance and end-product quality This is the second IQ Quality Control system for Papeterie Le Bourray’s mill. The first was for its TM4 machine, which was started

Indonesian paper maker PT Mega Surya Eratama has ordered fulloptional end line equipment from A.Celli for its mill at Mojokerto.

After the equipment is installed in 2023 by the Italian supplier, the PM2 packaging paper line will produce an average of 1,360 tonnes per day of testliner and medium corrugated with a width of 6,700mm and basis weight ranging from 90 to 180 gsm, thus making it the most productive line in the country for this type of product.

A.Celli supply will include a PMT-designed pope reel, capable

up in September 2021.

Valmet has also supplied distributed control system to Papeterie Le Bourray in 2016.

“Papeterie Le Bourray is our long-term customer with very specific needs,” says Eric Butreau, sales manager for the automation business line at Valmet.

“We are pleased to supply the quality control system to improve their quality. Our online measurements and controls will increase the stability of their production. With our combination of process know-how and strong service, we are confident that we will fulfill their expectations.”

Papeterie Le Bourray’s SaintMars-La-Brière mill dates from the 1840s and produces premium quality white and coloured tissue paper. In 2019 the mill became independent, still focusing on tissue production and also investing to develop recycled fibre production.

A.Celli is supplying a rewinder for PT Mega Surya Eratama’s mill in Indonesia of processing rolls with a diameter of 4,400 mm at a design speed of 1,350 m/min, and an E-WIND P100 paper rewinder.

Processing reels at 2,600 metres per minute, the rewinder is equipped with an in-line unwinder and four in-line reel parking stations, an automatic spool parking, a web-in Slittomatic system for the automatic positioning of the slitting units and, finally, tail and core gluing systems.

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Pulp Paper & Logistics

Analysis equipment upgraded at SCA’s Ortviken paper mill

SCA’s new CTMP mill at Ortviken will be a state-ofthe art facility producing market pulp with a capacity of 300,000 tonnes

A

s part of the upgrade of SCA’s Ortviken paper mill to produce CTMP market pulp with capacity of 300,000 tonnes a year, more analysis equipment has been ordered from PulpEye. In 2006, SCA bought three PulpEye online pulp quality analysers with modules analysing fibre, freeness and shives for the

mill’s TMP plant.

The latest order comprises two DotEye analysers, upgrading of the existing PulpEye analyser equipment and renting of a CrillEye module.

In addition, two DotEye analysers will be installed to make sure that the pulp products are as clean as possible.

The CrillEye technology, once

developed by STFI in Sweden and now produced and sold

by PulpEye, has proved to be a useful module when measuring the amount of crill in a pulp suspension. Crill has a great influence on paper and board strength properties as well as on bulk. As a part of the agreement SCA will therefore rent a CrillEye module to evaluate its potential

As a part of the PulpEye delivery two DotEye analysers will be installed at SCA’s new CTMP mill for the coming Ortviken CTMP mill.

“SCA Ortviken has for more than 15 years relied on PulpEye analysers for their TMP production,” says Öjvind Sundvall, managing director of PulpEye. “In order to be efficient and deliver top quality pulp products, it is important to have a robust and fast 24/7 online quality control. The upgraded PulpEyes, complemented with two DotEye analysers, will give the new CTMP plant a pulp quality control second to none.”

United Pulp and Paper starts up new OCC line A complete OCC line has been started up by Andritz at United Pulp and Paper Co (UPPC) for its mill in Bulacan, the Philippines.

Supplied on an EPS (Engineering, Procurement, Supervision) basis to the SCGP subsidiary, the line has a design capacity of 870 admt/d and processes old corrugated containers and mixed wastepaper as raw material to produce corrugated medium.

Detailed engineering and supply March/April 2022

of all auxiliaries for the line were also part of the project.

The stock preparation system features an Andritz pulping system comprising a FibreSolve FSR pulper with FibreGuard detrashing system to provide top performance, even when handling highly-contaminated furnish.

Fractionators and fine screens are equipped with innovative PrimeRotors for excellent removal of stickies with lower energy

consumption than conventional rotor types.

Pornchai Kumpeesirivutikul, project manager at United Pulp and Paper Co, commented: “Despite the pandemic, our new line was started up successfully. Andritz supervised the installation remotely and managed to support the start-up on site – this worked exceptionally well! We are absolutely convinced that we

will achieve our profitability and sustainability goals in the very near future.”

SCGP is a leading multinational provider of top-quality consumer packaging including fibre-based packaging, performance and polymer packaging (PPP) and foodservice packaging, as well as various pulp and paper products.

SCGP operates production mills in Thailand, Vietnam, Indonesia, the Philippines, the UK, and Spain.

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Pulp Paper & Logistics

New headbox for PM2 line at Naini Papers to raise productivity

N

aini Papers Limited in India has ordered a new headbox from Valmet for the PM2 line at its Kashipur mill.

The investment has been made to strengthen Naini Paper’s capability in delivering highquality paper to its customers and secure its market position with growing productivity.

The delivery is scheduled for December 2022, and the start-up in the first quarter of 2023.

The delivery includes an OptiFlo Fourdrinier headbox and an IQ Dilution Profiler with CD controls.

The single layer headbox with a dilution system will improve web profiles, formation, and productivity of the machine. It will have an operating speed of 900 m/min and a wire width of 3,260 mm.

“We expect to achieve quality improvement and production enhancement with this new headbox supplied by Valmet,” says Pawan Agarwal, managing director of Naini Papers Limited.

“The headbox rebuild will help

New Valmet headbox at the Kashipur mill will increase operating speed to 900 m/ min

Naini Papers to reduce energy consumption through less breaks, to achieve materials savings through furnish optimisation and

to improve profile uniformity for better paper quality. We are very happy to start working with Naini Papers and are looking forward to a successful project together,” says Varun Jain, director of the

India Region at Valmet.

Naini is a market leader in producing single layer cup stock, for making paper cups, and saturating kraft, for making laminates.

Repeat order for heat recovery chains at ICT Poland ICT Poland is having two heat recovery chains for its PM12 and PM14 tissue machines at its mill in Kostrzyn delivered by Andritz.

The heat recovery chains will be supplied by Andritz Novimpianti and include a PrimeDry YES Yankee Ecosteam system that produces high-

pressure steam by utilising exhaust air from the Yankee hood. This steam is used directly as motive steam for the Yankee, thus reducing energy costs and carbon dioxide emissions. Start-up is scheduled for 2022.

With a capacity of about 620,000 tons per year, ICT

is one of Europe’s leading tissue producers and has been using Andritz equipment and services since 2001 when the PM11 tissue line was installed at the Kostrzyn mill.

ICT Poland is having two heat 4 recovery chains installed at its mill in Kostrzyn March/April 2022

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Equipment for fluting line at Shanying Paper in China

K

ey equipment for a new packaging paper machine at Shanying Paper (Jilin) Co in China is being supplied by Italy’s A.Celli Paper.

The equipment includes a number of PMT ÆGO branded systems, such as a Stream S headbox equipped with the Smarpro dilution control system, a Form T top former, a shoe press with Tri-nip configuration and a Sizer FO size press. Two E-Wind P100 rewinders and a core handling system will also be supplied.

A.Celli Paper and PMT will handle the design and production processes respectively and the expected delivery is in about 12 months.

When started-up, the paper machine will have capability to produce fluting with a basis weight ranging from 70 to 170 gsm and web width of 7,300mm, produced

For Shanying Paper’s new packaging paper machine, equipment will be provided by A.Celli at a design speed of 1,100 m/min.

Wang Xin, project manager of Shanying Paper (Jilin) Co, said: “The core of this project is a line designed for the production of packaging paper with low basis weight. In particular, the shoe

press with the tri-nip configuration will guarantee a higher production flexibility and product quality while reducing energy consumption.”

Zhan Zhengfeng, general manager of Shanying Group’s

business department, added: “We are very happy to sign this cooperation agreement and we believe that the combination of PMT and A.Celli technologies can provide Shanying with excellent results.”

Sonoco to expand uncoated recycled paperboard capacity Diversified paper packaging manufacturer Sonoco is expanding its uncoated recycled paperboard (URB) capacity with the conversion of a corrugated medium machine to produce URB. As part of the investment, the machine at Sonoco’s Hartsville, South Carolina global headquarters will have Italy’s A.Celli Paper supply two E-WIND P100 paper rewinders and an R-WAY automated March/April 2022

material handling and packaging system.

E-WIND P100/P100H paper rewinders can be supplied at widths up to 8.4m, design speeds up to 2,600mpm and for basis weights up to 700gsm.

The comprehensive R-WAY integrated system will provide flexibility and productivity both in the handling and packaging of multiple products and in the style of packaging.

Automatic guided vehicles

supplied by A.Celli will be used to reduce labour, increase workplace safety, and reduce damage to both products and mill site structures. A fleet of four vehicles will automatically manage the transport of the parent rolls from the paper machine to the rewinders, as well as the handling of finished reels to the warehouse.

Tim Davis, vice president and general manager of Sonoco, commented: “We are eager

to see the results of this partnership. We are confident in the superior quality of the technological solutions offered by A.Celli in the field of winding, reel handling and packaging.”

Founded in 1899 and with about 300 plants in 34 countries, Sonoco produces consumer, industrial, healthcare and protective packaging with annual sales of US$5.2 billion.

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Technologies for Klabin’s Eukaliner brown pulp mill in Brazil started up

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ulp production and chemical recovery technologies have been started up by Andritz at Klabin’s Eukaliner brown pulp mill in Paraná state, Brazil.

The Puma II line at the Ortigueira mill was started up in the fourth quarter of 2021, almost on schedule despite the impact of the worldwide pandemic.

The project included: c A wood processing plant with debarking and chipping line, capable of processing both eucalyptus (350 cubic metres sob/h) and pine (400 cubic metres sob/h), meaning that a log truckload of wood is emptied onto the line every ten minutes. c A Herb recovery boiler with a capacity of 3,300 tds/d and high steam parameters of 103 bar(a) and 502 deg C to maximise power generation. It is equipped with an autonomous Smart soot blowing control system that combines Smart sensors (HEWI) and controls to ensure

the cleanability period, a higher availability of the boiler, as well as greater operating safety. c A power boiler based on EcoFluid bubbling fluidised bed (BFB) technology with a steam production capacity of 220 t/h.

It is combined with the recovery boiler to form a ‘boiler island’, and some of the auxiliary equipment is shared between the two boilers to make savings in investment and operating costs. c A complete white liquor plant consisting of a recausticising plant (5,000 cubic metres/d) and a LimeKiln (450 t/d) with a multi-fuel burner.

“We are very satisfied with the way we were able to manage and finish the project and start our key equipment for the Puma II line together with Andritz, despite the hardships of the Covid-19 pandemic.”

Francisco Razzolini, Klabin’s director of industrial technology, innovation and sustainability, added: “Klabin, along with its partners, has extensive expertise in creating solutions that contribute to the processes

Pablo Cadaval, general mill manager of Klabin’s Puma Unit, commented:

The Puma II line at Klabin’s Eukaliner brown pulp mill in Brazil has been started up

Grade conversion rebuild for VPK’s Alizay mill in France A fine paper machine at VPK’s Alizay mill in France is being rebuilt to produce recycled lightweight containerboard by Valmet.

Alizay says the move – with start-up planned for the end of 2022 – will support its plans for long-term sustainable development in the circular economy.

The grade conversion will include a new approach flow system, modifications to the headbox, a shoe and blade technology upgrade in the forming section, and a new OptiPress Center press section to improve drying and runnability.

The drying section will be updated into OptiRun Hybrid.

The delivery will also include

of pulp and packaging paper production. Andritz is one of the great examples, which – besides being fundamental to the entire production area – also proves to be a reference in optimising processes, with cutting-edge technology.”

an extensive air systems upgrade. The delivery will be complemented with improvements in the automation system, including machine control systems, sectional drive control systems, quality management systems, process control systems, and a paper machine clothing package.

The board machine with a

9,550mm-wide fabric will produce fluting and testliner grades with a basis weight range of 75-135 g/ sqm. Design speed will be 1,300 m/min with an annual capacity of 450,000 tonnes.

Belgium’s VPK Group, which produces recycled paper, corrugated cardboard packaging, solid board packaging, and cores, acquired the Alizay mill in Normandy from Double A in June 2021. In France VPK has three paper mills, nine corrugated box plants, and one core winding plant.

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New chief technology officer for Voith Paper

D

r Michael Weiss has been appointed as chief technology officer at Voith Paper.

Most recently vice president of business and research, Dr Weiss succeeds Frank Opletal, who is retiring after 38 years at the Germany-based engineering group.

Since 2006, Dr Weiss has held a number of positions in the development of pioneering technologies and innovations at Voith Paper. As vice president of new business & research, he has been in charge of innovation management, the simulation department and the central laboratory at Voith Paper since 2017.

Born in 1970, Dr Weiss studied process engineering at the RWTH Aachen University. He completed his PhD in chemical engineering in 2004 at the University of Oxford, UK, followed by a two-year period in France as a postdoc in industrial

Dr Michael Weiss, Voith Paper’s new chief technology officer research and development.

As CTO, Dr Weiss will drive Voith Paper’s innovation strategy within the differentiation criteria of sustainability, efficiency and fullline supplier.

Dr Weiss reports to Andreas Endters, president and chief executive of Voith Paper. Said Endters: “Especially today, the paper industry needs more innovations to make production more efficient and sustainable.

With his experience and his visionary view of the possibilities that lie in the sustainable material paper, we are pleased to appoint Michael Weiss to the management board.”

Melia chairs the Recovered Paper Council at the CPI John Melia is the new chair of the Confederation of Paper Industry (CPI) Recovered Paper Council.

Melia, who is director of DS Smith’s strategy development & innovation for European recycling activities, is also director of strategy development & innovation at the Recycling Division of the CPI. With more than 25 years of expertise in operations and strategic planning, Melia will chair the committee that advocates for a legislative and regulatory system that helps to drive a more sustainable paper industry.

CPI is the leading trade association working on behalf of the UK’s paper-based industries, promoting paper’s value as a renewable and recyclable resource.

Melia commented: “As a leading sustainable packaging company, we [DS Smith] need to work closely with associations and alliances such as CPI and

John Melia of DS Smith is to chair the Recovered Paper Council at the CPI 4evergreen, collaborating with institutional and industry stakeholders and clarifying guidelines for producers. I’m looking forward to working together with other industry experts to advise and help establish a system that ensures the circularity and high quality of fibre throughout its value chain from producers to recyclers.”

Recently, Melia was also elected to represent the Pulp Producers, Paper and Board Manufacturers & Recyclers Segment in 4evergreen’s steering group, which provides strategic direction to the alliance and oversight of its activities.

Management changes at Paper Converting Machine Company Several key management roles have been filled at Paper Converting Machine Company (PCMC) in Green Bay, Wisconsin, to align with Barry-Wehmiller’s Converting Solutions platform which is growing local operations and expanding its global footprint.

Scott Bean has joined as executive vice president of operations. He will drive manufacturing capacity and excellence across the platform’s five facilities in Green Bay, its March/April 2022

PCMC’s new appointees (l to r): Scott Bean, Jason Hilsberg and Kelly Morgano European locations at Lucca in Italy; Neuwied in Germany; and Čačak in Serbia.

Jason Hilsberg, who joined PCMC in 2003 as a field service leader and has held numerous

other roles, including sales director, is now vice president of lifecycle support and will lead the global field service, customer technical support and equipment modification sales teams.

Kelly Morgano has joined as global vice president of people and will lead the human resources, culture, communications and people development functions, while supporting the platform’s commitment to caring for team members.

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