pulp-paperworld magazine issue 7

PULP-PAPERWORLDissue 7 - February 2012

Metso’s - A vote of confidence in

performance-based mill maintenance

Total Tissue Capability - Improving the economic performance and quality of tissue operations

Photo: courtesy of SAICA.

ABB wins five-year Full Service agreement in South Africa with

Nampak Corrugated

Sonoco Recycling Names Fruit of the Loom® a Sonoco

Sustainability Star Award Winner

Paptech is a new event concept for the pulp and paper industry which provides an intimate, targeted and business-oriented platform. This is a two-day forum where suppliers and buyers meet and do business in a creative and relaxed atmosphere and where quality counts more than quantity. There will be inspiring seminars, a stimulating social pro-gramme and focused matchmaking.

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Based on several years of successful outsourced maintenance at its Zaragoza mills, Saica has contracted Metso Mill Service (MMS) to be the sole provider of maintenance services, from the recovered paper conveyors to the new reel warehouse, at its new 400,000 tpy Partington, UK mill, near Manchester. The concept focuses on a machine performance and productivity model which has been partially tested in Spain. Reductions in technical lost time and a safer working environment have been achieved.

TEXT Mark Williamson, Journalist Engineer

A vote of confidence in performance-based mill maintenance

The PM 10 machine at the El Burgo mill is one of five Saica machines in Spain covered by the MMS maintenance agreement.

26 3/2011 RESULTS PULP & PAPER

When Saica Paper’s new Partington, UK recycled furnish containerboard mill starts up in the first quarter of 2012, the entire mill will be maintained by Metso Mill Service (MMS), the maintenance arm of Metso. This is a strong vote of confidence in the concept of outsourcing and in the cooperation which has contributed to improving maintenance management at Saica over the past few years.

MMS will take over responsibility for maintenance operations and the manage-ment of improvement programs for the OCC stock preparation system, the board production line, power generation plants and the wastewater treatment plant. Saica had previously selected Metso as the main machinery and automation supplier for the 8.2-meter-wide, 400,000 tonnes per year production line, numbered PM 11.

Federico Asensio Balet, Deputy Managing Director of Saica Paper based in Zaragoza, Spain explains why this agreement is the ideal solution for the mill: “Our agree-ment with Metso at our new Partington mill

combines all aspects of corrective, preven-tive and predictive maintenance, and is a win-win situation. It adds value to our main-tenance activities to have an experienced paper machinery manufacturing company as our partner. This agreement gives us the best quality service, low costs, low downtime and the productivity we need to be successful. And furthermore, it covers the complete production line from the raw material conveyors to stock preparation to the new paper warehouse. The drivers of this agreement are very tightly connected to the mill’s overall production,” he says.

This comprehensive whole-mill agree-ment was carefully considered by Saica as it had to be based on shared common goals, mutual trust and the proven good working relationships developed between Saica and Metso. The business model for performance-based maintenance by MMS has its roots within Saica’s Spanish organi-zation centered in Zaragoza, where it has been developing and maturing since 2005.

Left to right: Ramón Muñoz of MMS, with Luis Miguel Garcia, David Plou, Federico Asensio, and Pedro Jariod of Saica.

The Saica El Burgo de Ebro mill in Spain.

Performance-based maintenanceSaica has two containerboard mills in the Zaragoza area: the Zaragoza city mill with two paper machines, and the El Burgo de Ebro mill, about 25 km away, with three pa-per machines. The combined production of the mills is 1.8 million tonnes per year.

Before Saica formed an agreement with MMS, the mill service was done mainly by four outside contractors. But Saica managers realized that maintenance must have a value-added component above and beyond just paying for the labor costs. Costs of work and spare parts should be managed and predictable, of course, but the maintenance activities should be more focused on reducing technical downtime and actually improving the paper making operation. Ensuring a safe working envi-ronment was also at the top of the list, as advocated by Saica’s motto: “If it’s not safe, it’s not Saica.”

Asensio highlights the reasons for forming the initial performance-based maintenance partnership with Metso.

“We needed a partner like Metso that would improve our knowledge of how to service our processes, so our maintenance procedures would be top-quality. Metso would bring this depth of paper machinery knowledge, their skills, diagnostic proce-dures and service methods, to add value. We would not be just buying hours of maintenance time. The end result would be good performance for our papermak-ing equipment.”

In 2005, Saica and MMS formed a partnership that would address mainte-nance from a performance point of view.

continued overleaf…

The roll maintenance shop is on the site of the El Burgo de Ebro mill.

The waste-to-energy power plant in the U.K.

Both companies invested money in the new organization. The staff of four previ-ous contractors was merged into one. To improve the level of skills and methods of service, Saica and MMS developed an extensive training plan which continues to-day. In the period from 2006 to 2009 about EUR 300,000 were invested in training, and the budget for 2010 was EUR 70,000.

The current 180 maintenance special-ists are located in three maintenance facilities: a roll maintenance shop and an electrical maintenance shop close to the El Burgo mill site, and a general mechanical maintenance shop located near Zaragoza. The mechanical maintenance and roll maintenance shops are set up as profit centers, and actively solicit and accept re-pair projects from other paper mills in the Iberian Peninsula and other parts of Europe, too. Other industries are served as well.

Investment in high-quality equipmentSkills are important, but diagnostic and machining tools are essential for a maintenance organization to perform at a top-quality level. In this respect, Metso has invested heavily in state-of-the-art equip-ment to provide high-quality refurbished

and refinished paper making equipment.The roll maintenance shop, opened

in 2007 near Zaragoza, boasts one of the most precise roll grinding machines in Europe. Equipped with a four-dimensional roll measurement and control system, the grinder can handle the largest rolls with a shell width of up to 11 meters and a weight of 120 tonnes. The roll maintenance shop also has a dynamic roll balancing machine which handles 11-meter-shell-width rolls of up to 30 tonnes. With this precision equip-ment and a high level of personal skills, the Zaragoza roll shop has been rated as the best in the Iberian Peninsula by custom-ers. Since its inception, over 700 rolls have been processed.

proved worker safety. Saica and MMS have therefore developed key performance indi-cators (KPIs) which show the effectiveness, quality and cost of maintenance, and the deployment of preventive safety actions.

In addition to general mechanical main-tenance Saica identified key process equip-ment that was problematic and needed special attention. It included felt-cleaning showers, doctoring (alignment and angle-setting procedures), and dryer fabric continuous cleaning systems. Recently, a committed maintenance concept has been applied to the stock preparation area.

David Plou, Maintenance Director at both Zaragoza area mills, comments on the working relationship with MMS while tackling specific problems: “We openly dis-cuss the specific problems and solutions. It has helped us to improve our depth of knowledge of the process and to reduce lost time due to mechanical reasons. We’ve also seen a close team spirit develop between the papermakers and the main-tenance people. As for safety, MMS shares our safety program goals.”

Diagnostic testing equipment abounds in the workshop. This includes vibration analysis, ultrasonic, thermal imaging and endoscopic video equipment. Precision mechanical alignment has also proven to be a valuable tool.

The mechanical workshop provides specialized refurbishing services for a wide variety of pulp and paper equipment including gear boxes, disk filters, stock prep equipment, screens, screw presses, vacuum pumps, and refiners.

Performance is keyOf course, the result of these investments in personal skills and equipment should be better paper machine uptime and im-

The roll grinding machine is one of the most precise in Europe.

The PM 11 machine at Partington is now under construction. The start-up is scheduled for the first quarter of 2012.

Asensio adds his thoughts on the cooperative spirit at the Zaragoza mills,

“We expected MMS to provide continuous step-by-step improvements for mainte-nance services in specific areas. Saica has developed and established, together with MMS, service actions to improve machin-ery performance and availability. This has meant a huge change in maintenance strategy – from reactive to proactive, and from a concept of outsourced labor to one of added-value maintenance services,” he concludes.

Overall, the mechanical lost time has improved steadily and lost time accidents have been reduced over the last few years. Using the years 2006 and 2007 as a baseline, time lost on equipment under the service agreements due to mechanical reasons has been reduced by 58%, while injury lost time has been reduced by 55%.

Partington next in lineThe concept and results of performance-based maintenance are well-established at the Zaragoza mills and a good level of trust has been established. Saica is in the process of establishing a program at its Venizel containerboard mill in Northern France, where MMS will manage the

The maintenance agreement for Partington was signed by Federico Asensio (left) from Saica and Barry Brown from Metso in January 2011. In the back from left to right: Luis Miguel Garcia, Pasi Häyrynen, Darren Hoyle, Paul Lilliot from Saica, Ari Telama, Jukka Koiranen, Juha Hentunen and Jan Vales from Metso.

mechanical maintenance on the OCC stock preparation area. And, of course, the next big step will be the implementation of the agreement at the Partington, UK mill.

Rather than building on-site mainte-nance shops the roll maintenance and mechanical repair works will be done by Metso’s existing shops in Darwen and Haslingden, which are both less than 50 km from the mill. At the same time Metso is upgrading and modernizing the Haslingden workshop.

MMS will play the managing role in mechanical, electrical and process control maintenance. Other site services provided

by subcontractors will be managed and cost-controlled by MMS. There will be Saica on-site people who will coordinate main-tenance activities and handle investments in the necessary equipment and process upgrades.

Moving into the new agreement, Asensio is confident that the whole-mill mainte-nance concept will work well. Problems will have to be addressed, of course, but the team spirit established at Zaragoza will carry through. “It’s a no-fault situation. Our teamwork with Metso is important since, if a problem occurs, we will work together as a single team to identify and solve it as quickly as possible,” he concludes.

Jukka Koiranen Maintenance Outsourcing technology unit Tel. +358 40 545 6173 [email protected]

Total Tissue Capability - Improving the economic performance and quality

of tissue operationsSignificant economic benefits can accrue from identifying and controlling process instability in tissue mills. BTG propose a highly collaborative project approach to delivering these benefits with the focus

on the potential outcomes for the client.

The goal is to introduce a practical methodology to help the tissue maker create economic value by identifying and controlling process instability. Ultimately, this could mean the tissue maker delivering more good quality cases of tissue per unit of installed capacity, but there may also be an intermediate

focus on reducing raw material, energy or consumable costs.

TEXT Ian Padley, Tissue Applications Manager, BTG Eclépens S.A.

Value in the Tissue Industry

Our approach has its basis in the appreciation of the economic factors involved in tissue making. Technical suppliers to the pulp and paper industry are too often concerned with the direct application of their product or service, and not nearly enough concerned with the economic

impact of its application. On the other hand, some purchasing decisions are based only on cost and make no attempt to define the value a product may bring.

An economic model which considers Cost in the context of Market, Quality and Output may be helpful. It serves to identify the true value of a product or service and avoid purely cost-based decisions or an overemphasis on technical specification without considering their economic impact.

The Market should be our first consideration, as it is from this that all else follows. Tissue covers a wide spectrum of commercial activities, from away-from-home to consumer tissue, branded or private label, different grades, etc. etc. Add to this the complexities of competition and the distribution channels for the tissue and it is clear there are many economic factors to understand before approaching the tissue manufacturing process.

Some generalities can be stated: premium branded producers will emphasize the very best quality above all else, giving the consumer ‘reason to believe’ in marketing parlance. On the other hand, private label producers are more than any other tissue producer part of the supermarket FMCG supply chain so need high production efficiencies and flexibility of operations to meet their customers’ demands. And the cost context of the model is very much influenced by the market position of the producer as we will see.

QUALITY needs to be fit for purpose in market terms. The premium producer’s brand will emphasize certain attributes: softness and handfeel, but also strength and sometimes even the length of the roll. Private label similarly has exacting, but subtly different specifications, this time defined by the supermarket buyer.

OUTPUT is of course a critical economic factor as fixed asset utilization has a big bearing on unit cost and hence gross margin. We can see that the productivity chain runs all the way back through to the tissue machine, with many issues manifesting themselves as converting problems, having their origin in the machine wet-end or even stock preparation area.

COST or cost reduction is a fact of life for this industry. Even here we need to view cost through the market lens. Do we mean cost of quality? The cost of output? Furnish, consumables, labor, energy, efficiencies all have their role to play, but the key is to take a holistic view of the total cost of operations in the context of the market drivers.

POSSIBLE OUTCOMES

The starting point for any project between the client and BTG will be to define the desired outcome for the client; for example an improvement in productivity or quality or a reduction in raw material or consumable costs. In all cases the basis is that an economic benefit will derive for the client.

The initial consultation would review this and start to explore the critical success factors to achieve this objective. A strategy based on technical solutions is proposed, and an agreement to a project would define the scope, equipment, personnel and project schedule as well as the cost: benefit statement and expected payback. Typically a project would run for 6 months, but complex issues requiring multiple specialties may take longer to execute.

A recent case study shows how the process works in more detail.

CASE STUDY: REDUCE CHEMICAL COSTS

In this case, the client had no chemical strategy in place, which resulted in multiple companies supplying products to the tissue machine with no integration or control. It was clear that many chemicals were being overdosed and thus the critical success factor was reducing the dosage without negative impact on machine operation or product quality.

StrategyCharge measurement and control was the key to understanding and reducing chemical dosage. The priority was to optimize the function chemicals dosed to impart wet strength and dry strength to the tissue.

Tactics The tools used were zeta potential measurement and soluble charge measurement, using lab instruments. A new chemical addition strategy soon became apparent, employing a trash collector to neutralize chemical-consuming anionic charge and revised addition points at the area of maximum fiber receptivity. Following this, the same procedure was followed for the process chemicals. After the initial work by BTG specialists, the instruments were handed over and mill personnel were intensively trained in their use and interpretation of the results.

SummarySuch was the scope for improvement at this site that the chemical spend was reduced by over 40% and the project payback time was less than 2 months. Unexpected benefits in terms of reduced cleaning, chemical usage and much improved machine efficiency were realized also. In this case chemical spend was reduced by €800K/year.

RECOMMENDED ACTIONS

This example gives an insight into how a holistic approach to problem-solving in tissue mills with a strong focus on outcomes can quickly give a significant economic impact at the client facility.

Typically, operations management at a tissue manufacturing site have many day-to-day concerns and committing to a detailed analysis of critical success factors impacting economic performance takes some time. The strength of BTG is to augment the mill operations team for the period of a defined project and add their specialist skills to the process of improving performance without distracting from ongoing operations.

The issues we are able to help address include (but are not limited to): Improve converting up-time Reduce converting scrap rate Reduce machine web breaks Increase doctor blade life Improve fabric performance Reduce chemical consumption Improve fiber utilization Address quality issues and Product improvement

If you have concerns in these areas, we have no doubt that we can help.

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UPM launches a new service for all-in-one colour and workflow management

UPM will introduce a new service UPM ColorCTRL at drupa in May. The new workflow

management application is developed to support users in reaching the best possible print result on UPM Papers – each time. It is created in co-operation with market leading supply chain partners including the expertise of UPM’s technical field team, the best-in-class workflow system by Dalim Software and award-winning ColorServer technology by GMG in one application.

As a Biofore Company UPM strives for continues development and innovative solutions with added value. “UPM’s services are tailored to improve our customers’ business processes and to help them to reach their business targets – from efficiency and also environmental point of view. UPM ColorCTRL is an excellent example of this,” says Thomas Ehrnrooth, Vice President of Marketing and Communications.

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UPM ColorCTRL is a web based pdf workflow management application. It is the first full turnkey solution in the market which covers the whole pro-cess from the creation of the print ready pdf page to the final colour accurate print product. It is enabled through the use of optimised paper profiles by GMG. UPM ColorCTRL is a cost effective and easy to use cloud based solution. With a service based fee the user will get an access to an online tool, which enables them to control workflows between different collaborators.

The service comes with consultancy and has every-thing in one package including pdf approval col-laboration, version control, pre-flight checking, collaborative softproofing and colour optimisation. No investment or maintenance cost in local servers, hardware or software is needed.

“UPM ColorCTRL is an online service which al-lows easy collaboration with all partners in the value chain - from brand owner to advertising agency, publisher and printing house,” explains Gerd Carl, Project Manager for UPM ColorCTRL, and contin-ues: “UPM ColorCTRL cuts down the time to market for quality print products and gives users savings in time, materials and investment costs.”

DALIM SOFTWARE provides its ES workflow tech-nology for the UPM ColorCTRL workflow online platform and the GMG ColorServer engine secures the optimal print ready pdf quality. Proof to print match is obtained using the optimized GMG Color-Proof software within the package. Colour accuracy of the final print product will be achieved by always up-to-date UPM paper profiles, service setup and consultancy.

UPM is piloting the new service with selected cus-tomers during the spring and will introduce UPM ColorCTRL at the UPM stand in drupa.

Sonoco Recycling Names Fruit of the Loom®

a Sonoco Sustainability Star Award Winner

Palmetto Distribution Center achieves gold-tier award status by going landfill free

Sonoco Recycling, Inc., a wholly owned subsidiary of Sonoco and one of the largest packaging recyclers in North America, today

announced that Fruit of the Loom’s Palmetto Distribution Center, located in Summerville, S.C., has received a gold-tier Sonoco Sustainability Star Award for going landfill free.

“This is something we are very proud of,” said Jay Medlin, plant manager, Palmetto Distribution Center, Fruit of the Loom. “I challenged my team with the goal of going landfill free, and every employee in our facility has worked to help us hit our goal. From the early environmental education to the impact on daily operations, we could not have accomplished this without them.”

In announcing Fruit of the Loom’s achievement, Ray Howard, general manager, Sonoco Recycling, said, “Fruit of the Loom has demonstrated a strong commitment to preserving our planet’s natural resources, focusing on sustainability as an effort vital to the success of their business and their communities. We are honored to present them with a gold-tier sustainability award for this impressive achievement.”

To achieve landfill-free status, the Palmetto Distribution Center created a Green Team and began working on what they called their “Green on Green” initiative.

The Green Team focused on making sure all recyclable materials, such as cardboard, baled stretch wrap, miscellaneous plastics, cores and office paper were collected by Sonoco Recycling. Fluorescent lights were crushed in a secure manner and sent off for recycling, while batteries were sent for recycling through an approved vendor. The Palmetto Distribution Center also works with vendors to ensure that their pallets are reused internally. The small amount of waste remaining is sent to a local compost facility and garden, or used by a waste-to-energy (WTE) facility.

The team’s biggest challenge was food and miscellaneous waste, but it successfully managed to find uses for all waste materials. As of January 2012, the Palmetto Distribution Center has successfully gone from 70 percent landfill diversion in 2010 and 95 percent in 2011 to 100 percent landfill diversion.

Created to recognize customer and Sonoco facilities for achieving significant milestones in landfill diversion and waste stream reduction, the program is composed of three tiers:

• Gold Star Awards, which recognize facilities that have achieved 99 percent landfill diversion;• Silver Star Recognition, which is awarded to facilities achieving 95 percent landfill diversion; and

• Bronze Awards, which recognize facilities that have made significant waste reduction achievements.

A recycling leader with locations and expertise worldwide, Sonoco Recycling annually collects more than 3 million tons of old corrugated containers, various grades of paper, metals and plastics. In addition, the Company has experts who provide secure, reliable and innovative recycling solutions to residential and commercial customers.

Currently, Sonoco Recycling operates six material recovery facilities (MRFs) and serves nearly 150 communities in which curbside-collected residential and commercial materials are processed. The Company also provides recycling programs which identify waste reduction opportunities that reduce operating expenses for many of the largest consumer product companies in the U.S.

About Fruit of the Loom

Fruit of the Loom is a leading international, vertically integrated basic apparel and athletic goods company, emphasizing branded products for consumers of all ages. The Company, including its Russell Brands, LLC and Vanity Fair Brands, LP subsidiaries, is one of the world’s largest

manufacturers and marketers of underwear, intimate apparel, casualwear, athletic apparel and equipment for the entire family. The Fruit of the Loom companies sell products under a number of international brands including Fruit of the Loom®, Vanity Fair®, Russell Athletic®, Spalding® and Brooks®. For more information about the Company and its products, visit http://www.fruit.com.

About Sonoco

Founded in 1899, Sonoco is a global provider of a variety of consumer packaging, industrial products, protective packaging and packaging supply chain services. With annualized net sales of approximately $4.5 billion, the Company has more than 19,000 employees working in 340 operations in 34 countries, serving some of the world’s best known brands in some 85 nations. Sonoco is a proud member of the 2011/2012 Dow Jones Sustainability World Index. For more information on the Company, visit our website at http://www.sonoco.com.

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There for you!BTG is present throughout the Pulp & Paperprocess and committed to helping youachieve significant, sustainable gainsin business performance.

Contact us today to learnhow we can help improveyour bottom line!www.btg.com [email protected]

ABB wins five-year Full Service agreement in South Africa with

Nampak Corrugated

Contract with Nampak Corrugated to manage maintenance operations, increase productivity and energy efficiency at

paper mill

ABB, the leading power and automation technology group has signed a five-year, ABB Full Service® contract with Nampak

Corrugated, to manage maintenance and improve overall efficiency at the company’s Rosslyn Paper Mill in Pretoria, South Africa. Under the agreement, ABB will manage all maintenance operations at the paper mill to improve equipment efficiency and increase production output while reducing operating costs. 62 Nampak maintenance employees transferred to ABB when the contract took effect on December 1, 2011.

Nampak is Africa’s largest packaging company, manufacturing a diverse range of paper, plastic, metal and glass packaging products. The Rosslyn mill manufactures recycled based paper for a variety of corrugated packaging products, supplied by Nampak’s Corrugated operations.

Under the agreement, ABB will manage all maintenance to improve productivity and equipment reliability at the mill, and retain and develop all existing maintenance staff and management. ABB will train the staff in pulp and paper industry-specific predictive maintenance and management practices. In addition, ABB will provide process optimization, energy consulting, equipment lifecycle services at the site, as well as manage all third-party subcontractors and suppliers.

“ABB Full Service agreements make business sense in terms of increasing efficiency in operations, and help to further develop skilled maintenance personnel in world-class practices,” said Veli-Matti Reinikkala, head of ABB’s Process Automation division. “These agreements provide an exceptional win-win situation for all involved, and allow the customer to focus on their core business while getting the best performance out of their process.”

The agreement formalizes a joint vision in which ABB manages maintenance at the Rosslyn facility, while Nampak Corrugated Paper Mills strengthens its strategic focus on growing its core operations.

“We are not only looking forward to improved maintenance processes and practices, but the performance guarantees will ensure the relationship is a true partnership with the parties working closely together to improve operations, and value is added in a much wider context than pure maintenance services”, said Christiaan Burmeister, Managing Director of Nampak Corrugated.

This is ABB’s largest Full Service contract to date in South Africa. The new contract complements more than 100 ABB Full Service relationships with customers in the paper, metals, mining, chemicals, and oil and gas industries worldwide.

ABB (www.abb.com) is a leader in power and automation technologies that enable utility and industry customers to improve their performance while lowering environmental impact. The ABB Group of companies operates in around 100 countries and employs about 130,000 people.

For help with any technical terms in this release, please go to: www.abb.com/glossary

For more information please contact:ABB Process Automation Media Relations:

Laura PatrickOffice: +1.585.889.7146Mobile: +1.585.733.4958

email:[email protected]

http://www.abb.com/industries/us/9AAC910025.aspx

http://www.abb.com/glossary

mailto:laura.m.patrick%40us.abb.com?subject=Info%20on%20article%20in%20Pulp-paperworld%20issue%207

SMART 4.0 Technology, the world’s first system for dynamic nip measurement, is now available with new functionality for use in more positions and applications.

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Kemira Oyj Europe, Middle-East and Africa South AmericaPorkkalankatu 3 Tel +358 10 8611 Tel +55 11 2189 4900P.O. BoxFI-00101 Helsinki, Finland North America Asia-Pacificwww.kemira.com Tel +1 800 347 1542 Tel +86 21 3367 8333

SOLVED expert service aims to be the world’s leading cleantech community – Kemira is in!

All over the world people are struggling with environmental challenges. Cleantech Finland’s new SOLVED expert service at

www.solved.fi harnesses the Finnish problem solving ability and world-class technology expertise to solve them.

Cleantech Finland, operated by Finpro, is a network of Finnish environmental technology companies that has a goal to profile Finland as a top country in the field. Cleantech Finland’s SOLVED expert service brings together cleantech companies, clients and other interest groups, the problems and their solutions on an online platform that enables new ways to be active and cooperate.

“SOLVED aims to be the world’s leading cleantech community. Now we can be even more effective in channelling Finnish expertise to match global demand. Through the service companies get boost and visibility,” promises Santtu Hulkkonen, Cleantech Finland’s Executive Director.

Meeting place for top experts and challenges The experts from Cleantech Finland „s member companies play a key role in SOLVED. In the service anyone can ask questions, engage in discussion and do networking. The top experts from the respective field then provide the factual information,

perspectives and practical experience to solve a problem or take part in the discussion. About one hundred experts have already signed in the service. Also Kemira has experts among them.

”Problem solving ability is a known part of the Finnish heritage. We have the competence, the cooperational abilities and the natural willingness to do things as efficiently and well as possible. In SOLVED this way of doing things and Finnish expertise come together in a fascinating and easily approachable whole,” Santtu Hulkkonen says.

Kemira is a global, over two billion euro, chemical company that is focused on serving customers in water-intensive industries. The company offers water quality and quantity management that improves customers energy, water, and raw material efficiency. Kemira’s vision is to be a leading water chemistry company.

More information

Cleantech Finland, Santtu Hulkkonen, Executive Director [email protected], +358 40 343 3341

Kemira Oyj, Arja Vanhanen, Director, Product Marketing [email protected], +358 50 509 1680

FOR AND ABOUT PEOPLEAT PIGMENTS FOR PAPER

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For and about peopleat Pigments for Paper

Europe

Tel: +358 20 757 7700�

Asia Pacific

Tel: +65 67 99 60 60� � Internet:

www.imerys-paper.com

N. America

Tel: +1 770 594 0660�

S. America

Tel: +55 11 2133 0055�

ADDING VALUE TO PAPER

design: sheardhudson.com

Metso-supplied containerboard line starts up at Saica Containerboard in the UK

The Metso-supplied complete containerboard production line, PM 11, for Saica Containerboard UK Ltd., successfully came

on stream on January 15, 2012 at Partington, near Manchester in the United Kingdom. The record-breaking start-up speed was 1,105 m/min with a basis weight of 95 g/m2.

Three days later, on January 18, the first sellable paper reels were produced and tested, leaving the mill and reaching the first customers shortly afterwards.

Francisco Carilla, Industrial Projects Director, Saica, and Federico Asensio, Deputy Managing Director, Saica Paper, are both very satisfied with the Metso teams of all project stages:“In commercial proposals, design, construction, start-up and maintenance activities the Metso teams’ efforts responded to our requirements, taking into consideration our papermakers’ technical advice and previous projects experiences.”

“We are sure the high level of cooperation achieved between Saica and Metso will create significant added value for the further optimization of the

production line. This will allow Saica to deliver high-quality lightweight containerboard paper to our customers setting the standard for these grades in the UK and in Europe.”

The new 8.2-m-wide PM 11 has an annual production capacity of approximately 400,000 tonnes of lightweight testliner and fluting grades in the basis weight range of 75 to 125 g/m2, out of 100% recycled raw material. The design speed is 1,700 m/min.

Metso’s delivery included a complete OptiConcept board making line from headbox to reel with an approach flow system, pulpers, air systems, press section clothing as well as a high-capacity WinDrum Pro winder.

A comprehensive Metso DNA automation package comprised process, machine and quality controls as well as machine condition monitoring. A Metso DNA process control system was also supplied for the mill’s new heat and power station and effluent treatment plant.

Metso Mill Service will have full responsibility for the mill maintenance operations as well as

for maintenance management of continuous improvement programs for the OCC stock preparation system, board production line, power stations and wastewater treatment plant at the Partington mill.

Saica Containerboard UK Ltd., is a subsidiary of SAICA, a privately owned Spanish company and a world leader in the production of corrugated containerboard from recovered paper. The company currently employs over 8,000 people in Spain, France, Portugal, Italy, Ireland and the UK. SAICA has an annual turnover of EUR 1.8 billion.

Metso is a global supplier of sustainable technology and services for mining, construction, power generation, automation, recycling and the pulp and paper indus-

tries. We have about 29,000 employees in more than 50 countries. www.metso.com

http://www.metso.com

http://www.xerium.com/

http://www.evgroup.fi/en

http://www.evgroup.fi/en

http://www.enessco.com

http://www.runtech.fi

Imerys has developed a platform of platy clays fromMiddle Georgia with large plate diameter and thin crystaldimension that can deliver unique value in a variety ofpaper grades.

These clays are covered under patented technology and are available in a range of particle sizes and shape factors. Their

extreme shapes allow them to interact more effectively with blockier particles such as ground and precipitated calcium

carbonates in order to provide: bulkier structures with optically effective pore sizes, improved coating hold out, and better

coverage from the larger plate diameters.

E500 and E800 are premium coarse pigments specifically designed to provide

coating coverage and build coating bulk in precoating or low gloss

applications. They work especially well when blended with blocky co-

pigments such as GCC. The improved coverage can allow papermakers to

reduce calendering and thus improve sheet bulk, or apply lower top coat weight.

EuropeTel: +44 1726 818000

Asia PacificTel: +65 67 99 60 60

N. AmericaTel: +1 770 594 0660

S. AmericaTel: +55 11 2133 0055

[email protected]

Internetwww.imerys-paper.com

E100, E160 , E270 and E300 are premium fine platyclays developed for a variety of applications.They can work well in single coating LWCapplications, or can also be used in pre-coatapplications when blended with blocky co-pigments.

Name Recommended % < 2 µm Brightness Solids (%)Paper Grade/Market (GE)

E800 CWF Precoat 72 86.5 57


E300 LWC or Board/CWF 84 87.5 61Precoat

E100 LWC or Board/CWF 90 87.5 63.5Precoat

E160 LWC 90 87.5 65.5

E270 LWC 91 88.0 64.5

Summary

E-Type™ Clays are uniqueImerys patented technology

Deliver unique properties and performance with hydrous kaolin

Coater typeThe E-Type Product line can be run on the following coaters:

– E300, E500, E800 - puddle size press, blade and rod

– E100, E160, E270 - puddle size press, blade, rod and MSP

Improved coating coverage in LWC meansBetter smoothness and gloss

Potential cost saving levers are:

– Reduced plastic pigment or lower coat weight

– Less calendering, which provides bulk and stiffness

– Covering a rougher base stock

Improved coating coverage in precoatBetter bulk and smoothness

Synergy when combined with blocky carbonates

Allows flexibility in top coat pigment design




– Less topcoat weight

– Potential to incorporate lower cost fibre to improve bulk and maintain smoothness

The benefits above potentially lead to “greener” papermakingand a lower carbon footprint for making paper

0

100

10065

Shap

e Fa

ctor

% < 2 micron

E800

E500

E300

E100

E270E160

© IMERYS - April 2010

E-TYPE - Plates inthe Extreme

E-TYPE - Plates in the Extreme

Benefits in LWC - What is theValue?

Improved coating coverage

Increased coating coverage per unit weight of coating

Leads to the following potential benefits

Increased smoothness and gloss

Increased opacity

What can the papermaker do?

Reduce coat weight

Remove plastic pigment and/or TiO2

Reduce calender loading

– Bulkier sheet with better stiffness

– Less calender darkening

Cover a “rougher” base sheet

Replace latex with starch - (i.e. smoothness benefit offsets theproblem with starch shrinkage)

All of the above can reduce cost or improve quality

E100 Clay in LWC Offset

Building Structure with Platesand Blocks: Brightness and GlossBenefits in LWC

E100 Clay in LWC Offset

E100 versus standard delaminated clay in typical LWC

formulation with 4 pts plastic pigment

Improved gloss gives cost savings levers:

At constant gloss, coat weight can be reduced by ~ 1 GSM

At constant gloss, plastic pigment can be eliminated

Either option can give savings >$5 per ton of paper

Benefits in Precoat- What is theValue?

Improved coating coverage, blended with the right blocky co-

pigment

Increased coating coverage per unit weight of coating

Leads to the following potential benefits

Increased smoothness of the precoat, leading to higher glossin final coated paper

Increased opacity

What can the papermaker do?

Reduce top coat weight

Change top coat design

Reduce calender loading

– Bulkier sheet with better stiffness (possibly allowingless fibre usage)

– Less calender darkening

Hide a rougher base sheet

– Adjust fibre blend or fibre processing

All of the above can reduce cost or improve quality

E-Type™ Clays in WoodfreePigmented Size Press Coating

Building Structure with E-Type™Clays

The SEM freeze micrographs illustrate the cross-sections of two

precoats. Photo A shows the packed coating structure with

100% Carbital™ 60 GCC. Photo B shows the disrupted packing

structure of a multi-pigment coating containing Carbital™ 60

GCC and E-Type hyper-platy clay.

Note: Both SEMs have the same magnification.

3 4 5 6 7 8 9 10

70

65

60

55

50

45

40

35

30

Shee

t G

loss

Coat Weight (gsm)

Std. Delaminated

E100

67.5

68

68.5

69

69.5

70

30 35 40 45 50 55

Shee

t Br

ight

enss

Delaminated

E-Type and Blocky Co-Pigments

Sheet Gloss

94%

95%

96%

97%

98%

99%

100%

StandardDelaminated

E100 less 4 partsplastic

E100 lower coatweight

$5.80 per ton of paper

$5.20 per ton of paper

Cost Savings Potential

100% Carbital™ 60

50% Carbital™ 60 / 50% E500

Fine Blocky GCC particles dive into

the basesheet.

Large platy clays stay on paper

surface and bridge across fibers.


Imerys has developed a platform of platy clays fromMiddle Georgia with large plate diameter and thin crystaldimension that can deliver unique value in a variety ofpaper grades.

These clays are covered under patented technology and are available in a range of particle sizes and shape factors. Their

extreme shapes allow them to interact more effectively with blockier particles such as ground and precipitated calcium

carbonates in order to provide: bulkier structures with optically effective pore sizes, improved coating hold out, and better

coverage from the larger plate diameters.

E500 and E800 are premium coarse pigments specifically designed to provide

coating coverage and build coating bulk in precoating or low gloss

applications. They work especially well when blended with blocky co-

pigments such as GCC. The improved coverage can allow papermakers to

reduce calendering and thus improve sheet bulk, or apply lower top coat weight.

EuropeTel: +44 1726 818000

Asia PacificTel: +65 67 99 60 60

N. AmericaTel: +1 770 594 0660

S. AmericaTel: +55 11 2133 0055

[email protected]

Internetwww.imerys-paper.com

E100, E160 , E270 and E300 are premium fine platyclays developed for a variety of applications.They can work well in single coating LWCapplications, or can also be used in pre-coatapplications when blended with blocky co-pigments.

Name Recommended % < 2 µm Brightness Solids (%)Paper Grade/Market (GE)



E300 LWC or Board/CWF 84 87.5 61Precoat

E100 LWC or Board/CWF 90 87.5 63.5Precoat

E160 LWC 90 87.5 65.5

E270 LWC 91 88.0 64.5

Summary

E-Type™ Clays are uniqueImerys patented technology

Deliver unique properties and performance with hydrous kaolin

Coater typeThe E-Type Product line can be run on the following coaters:

– E300, E500, E800 - puddle size press, blade and rod

– E100, E160, E270 - puddle size press, blade, rod and MSP

Improved coating coverage in LWC meansBetter smoothness and gloss


– Reduced plastic pigment or lower coat weight



Improved coating coverage in precoatBetter bulk and smoothness

Synergy when combined with blocky carbonates

Allows flexibility in top coat pigment design




– Less topcoat weight

– Potential to incorporate lower cost fibre to improve bulk and maintain smoothness

The benefits above potentially lead to “greener” papermakingand a lower carbon footprint for making paper

0

100

10065Sh

ape

Fact

or% < 2 micron

E800

E500

E300

E100

E270E160

E-TYPE - Plates inthe Extreme


EV Group Oy Phone +358 (0)2 276 7670 Y-tunnus 2108597-1 www.evgroup.fi High Tech Centre 2 fax +358 (0)2 235 1863 VAT reg. FI21085971 Lemminkäisenkatu 50 first [email protected] FIN-20520 Turku

EV ReDoc Cleans the Cylinder Surface

Sonoco Alcore BM1 had produced paperboard for decades without any proper cylinder surface cleaning system. Contamination on cylinders surfaces resulted in remarkable loss of drying capacity and extra energy costs. To eliminate the problem, the mill decided to invest in one unit of EV ReDoc for cylinder and roll surface reconditioning. After every cleaned cylinder surface, the mill removes the EV ReDoc for the next contaminated cylinder. This means in one year the mill could clean as many as about 10 cylinders. The mill personnel is happy with the cleaning results. EV ReDoc has eliminated the dirt that was accumulated on the cylinder and calander surfaces over the years. Thanks to clean cylinder surfaces, drying is now more efficient and requires less energy than before. Also, the quality of the paperboard is improved. After the cleaning, the cylinder surfaces are still pretty clean after one year production time.

”EV ReDoc has cleaned properly all cylinder surfaces.” Mikko Grön, BM 1 Technical Manager

Sonoco Alcore BM 1

- Speed 200 m/min

- Width 3,0 m

- Grade core board

- Cylinders are cleaned with one, removable EV ReDoc unit

Before: Very dirty cylinder surfaces

After: Cyliner surfaces are as good as new

EV Group Oy Phone +358 (0)2 276 7670 Y-tunnus 2108597-1 www.evgroup.fi High Tech Centre 2 fax +358 (0)2 235 1863 VAT reg. FI21085971 Lemminkäisenkatu 50 first [email protected] FIN-20520 Turku

What problems are created because of dirty cylinder surfaces? The cleanliness of cylinder surfaces has a remarkable effect on drying efficiency. Contamination and dirt on the cylinder surface create an isolating layer that prevents efficient heat transfer to the paper. As a result, at a contaminated cylinder easily 7% additional energy costs are created because of drying steam waste. If the mill has many dirty cylinders, it means significant energy waste and additional costs! Dirty cylinder surface also easily creates uneven moisture profile and paper or board quality problems.

What is the operation principle of EV ReDoc? The steel brush collects the dirt in the bristles and stores it until the end of the cylinder surface. The dust and dirt will be removed from the brush when the brush reaches the end of cylinder surface. The tension of the brush is released and the brush throws the dirt away from the cylinder. Brushes do not create any deformation or erosion on the maintainable surface. Due to continuous reconditioning, rolls and cylinders stay as good as new. The line pressure towards the cylinder / roll surface is adjusted with the EV ReDoc fine adjustment unit. This is why even old and worn out cylinders can be cleaned effectively with the help of EV ReDoc, when conventional doctoring system is not able to keep cylinders clean.

What are the operational costs of EV ReDoc? It is very economical to use EV ReDoc. Basically, EV ReDoc should be used in positions where conventional doctoring does not bring any advantage. After the surface is cleaned, the brush consumption is minimal. Naturally, if there is need for more intensive cleaning, new brushes are required more often. The electricity consumption of EV ReDoc is only minimal, as the brushes and the chain are operated by a small motor (0.18 kW).

EV ReDoc brush types

Contamination on cylinder surface

Uneven moisture profile,moisture peaks

Elimination of moisture peaks with steam box, overdrying

DIRTY CYLINDER SURFACE MEANS ENERGY WASTE AND ADDITIONAL COSTS

Invitation to exhibit at

China Paper 2012The 20th International Exhibition and Conference

for the Pulp and Paper Industry in Asia

September 10–12, 2012INTEX Shanghai, Shanghai, China

www.chinapaperexpo.cn

China Paper features the newest equipment, tech-nologies and services related to all of Asia’s paper industries. Some 400 exhibiting companies and al-most 7,000 visitors from China and 50 other countries will once again be gathered in Shanghai 2012.

The Market China is today the largest paper producing country in the world.

Official statistics from 2010 show that there were more than

3,700 paper makers in China generating 92.7 million tons of

paper and paper board products, up 7.29% from 84.6 million

tons in 2009. The consumption of paper and paper board pro-

ducts was 91.73 million tons in 2010, up 7.05% from 85.69 million

tons in 2009.

In order to meet increasing demand and to run operations

effectively, Chinese paper mills are in great need of the latest

products, services and technology that you as a supplier have

to offer.

The ExhibitionTaking place annually, China Paper is the No. 1 pulp and paper

event for the Chinese and Asian markets. The show alternates

between Beijing and Shanghai and in 2012 China Paper will

celebrate its 20th edition. Exhibitors from the Americas, Europe

and Asia are represented as well as numerous domestic Chinese

exhibitors.

The VisitorsYou will meet top level decision makers and buyers from China’s

paper mills who have the budgets to make large-scale invest-

ments. According to the Visitor Survey of China Paper 2011 in

Beijing, 72% of the visitors are decision makers and company

Welcome to exhibit at the premier event for the Asian pulp and paper industry

managers. 60% of the visitors state that the reason for visiting

the exhibition is to look for new suppliers, place orders and

consolidate contracts. The number of visitors at China Paper

2011 in Beijing exceeded 6,600.

The ConferenceA key feature of the China Paper event is the renowned Tech-

nical Conference, co-organised by CTAPI (China Technical Associ-

ation of Paper Industry) and PI (Paper Engineers’ Association).

This one day conference will be held on the second day

of the exhibition, Tuesday, September 11. There will also be a

number of more business oriented seminars running in con-

junction with the exhibition.

China Specialty Paper PavilionThe specialty paper industry in China has been growing rapidly

in recent years and is continuously upgrading quality by en-

hancing the level of raw material, equipment, and techniques

through import and innovation.

At China Paper 2011 in Beijing the Specialty Paper Pavilion

was presented on a total of 400 sqm of new products, equip-

ment and services, and was visited by a large number of highly

qualified paper professionals.

The China Paper show in Shanghai has been and will be an important and strategic trade show for our company,

in order to maintain and expand our business in China and the rest of Asia. Marcus Pfeifle, CEO , CTP GmbH, Germany

Attendees at China Paper 2011 BeijingGraph 1: Attendee position within the company

Manager: 41%

Staff: 28%

Decision Maker: 31%

Graph 2: Attendee intention when visiting the show

Sourcing for new items and placing orders:

Consolidating contracts:

Looking for new suppliers:

Finding agent/Joint Venture partner:

Collecting market/product information:

Other:

Product areas on displayPaper Making Section• Bleaching• Chemicals• Coating• Construction• Data Processing• Engineering• Finishing• Maintenance and Components• Paper Machines• Process Controls• Pulping• Quality Control• Safety• Stock Preparation• Testing• Woodyard

Paper Product Processing Machinery• Pulp Molding• Paper Folding• Cutting• Winding• Paper Slitting and Rewinding• Laminating• Embossing

Environment and Paper Recycling• Recycling Equipment• Energy Saving• Waste Water Treatment• Testing Instrument

Speciality Paper• Fiber Materials• Equipment• Chemicals• Household Paper• Printing Paper• Producer• Special Paper Products• Tissue

Who will be attending?• Paper mills and related companies• Paper wholesalers and distributors• Paper merchants and importers• Newspaper publishers• Large-scale printers• Designers• Specifiers• Specialty paper users of various industries• Managers, chief engineers and technical personnel of specialty paper and pulp mills• Specialty paper machinery & supply distributors and agents

The Visitors The Exhibitors

0 10 20 30 40


Please use block letters. Take a copy for your own use.

VAT number

Name of company – Contracting party

Postal address and zip code

Country

Contact person

Telephone, direct Telephone, switchboard

Fax Website

Email, contact person

We hereby apply for:

p Option 1:.............. sqm of: Package Space/Complete Shell Stand, minimum 9 sqm.USD 490 per sqmThe package includes: exhibit space, walls, 1 information counter, 2 chairs, 1 waste basket, 2 spotlights, carpeted floor, 1 electrical outlet, sign panel in Chinese and English.

p Option 2:.............. sqm of: Raw Exhibit Space, minimum 15 sqm.USD 410 per sqm

Based on this registration, a contract will be issued and signed by both parties. Terms and Conditions included in the contract.

DateSend Registration Form to:

Adforum AB, SE-125 80 Stockholm, Sweden. Tel + 46 8 749 97 31. Fax +46 8 749 91 64.Email [email protected]

E.J. Krause & Associates, Inc. – Beijing Office, Room 2005, Capital Mansion, 6 Xinyuan Nan Road, Chaoyang District, Beijing 100004, P.R. China. Tel (+86-10) 8451 1832. Fax (+86-10) 8451 1829.Email [email protected] or [email protected]

Company name

Name of contact person

Signature

China Paper 2012, September 10–12, 2012INTEX Shanghai, ChinaThe 20th International Exhibition and Conference for the Pulp and Paper Industry in Asia

Registration Form

Media Partners:

General informationDates: September 10–12, 2012

Venue: INTEX Shanghai, Shanghai, China

• Package Space/Complete Shell Stand, minimum 9 sqm USD 490 per sqm The package includes: exhibit space, walls, 1 information counter, 2 chairs, 1 waste basket, 2 spotlights, carpeted floor, 1 electrical outlet, sign panel in Chinese and English.

• Raw Exhibit Space, minimum 15 sqm USD 410 per sqm

For more information and booking, please contact:General EnquiriesAdforum, Sweden Mr Patrik Lö[email protected]: +46 8 749 4361

Asia (except India)E.J. Krause & Associates, Inc., China Ms Phoebe [email protected]

Mr Peter [email protected]: +86 (10) 8451 1832


Conference co-organised by:Organised by:

China Paper is supported by• China National Council of Light Industry • China Technical Association of Paper Industry• Printing and Printing Equipment Industry Association of China• China National Council of Packaging Industry• China National Light Industrial Products Import/Export Corporation• Paper Industry Productivity Promotion Center Specialty Paper Committee• Shanghai Packaging Technology Association• Shanghai Technical Association of Paper Industry• Zhejiang Technical Association of Paper Industry• Jiangsu Technical Association of Paper Industry• Fujian Technical Association of Paper Industry• Shandong Technical Association of Paper Industry• Henan Technical Association of Paper Industry• Shanghai Paper Trade Association• Sinolight Corporation Household Paper Technology Center

China Pavilion organised by:

Cent

ral C

omm

unic

atio

n. P

hoto

: Mat

ton,

Adf

orum

arc

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and

CIE

C ar

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International Sales RepresentativesGermany, Austria and SwitzerlandMrs Annelie Bäck-HeuserBäck+Partner MarketingTel: +49-202-283 81 26Email: [email protected]

ItalyMrs Carla SalarisLighthouse S.r.l.Tel: +39 02 54189640Email: [email protected]

Spain/PortugalMr Eduardo Teixeira-AlvesTel: +34 96 3122197Email: [email protected]

South AmericaMrs Selma Regina Ugolini go.vaTel: +5511 2218-0005/0422Email: [email protected]

IndiaMr K.V. RajeevanInter Ads-Brooks ExhibitionsTel: +91-124 4524200Email: [email protected]

North AmericaMr Björn Bieneck Bieneck InternationalTel: +1 (540) 372-9800Email: [email protected]

PresScan™

The newest microwave technology to measure the water content in press felts accurately and reliably.

The instrument with the best value for money in the industry!

www.feltest.com

2007236 Feltest advertenties.ind2 2 10-08-2007 11:01:12Proceskleur CyaanProceskleur MagentaProceskleur GeelProceskleur Zwart

Professional Tools and Equipment for Paper Machine Clothing

visit www.feltest.com now

T : +31 313 652 215 - F: +31 313 654 068 - E: [email protected]

FiberScan™

The new microwave instrument to analyse the drainage of forming fabrics.

No more formalities, travelling is now as easy as A, B, C!

www.feltest.com

NON-RADIOACTIVE

2007236 Feltest advertenties.ind1 1 10-08-2007 11:01:03Proceskleur CyaanProceskleur MagentaProceskleur GeelProceskleur Zwart

Feltest Equipment BVFeltest Equipment develop measuring instruments and tools to help you improve the

performance of Paper Machine Clothing, like forming fabrics, press felts and dryer screens. Feltest products are used world-wide by all major Paper Machine Clothing companies

http://www.feltest.com



pulp-paperworld magazine issue 7

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