Paper Technology Journal - Voith

1 Paper Technology Journal10 News from the Divisions:Republic Paperboard Company the world s first Paper machine withtwo gap End process new technologysolutions around the Paper machinewet PM 1 strengthening ofFrohnleiten the online wind-up news: Voith S o Paulo, Culture:Festas do Povo, Campo FROM THE DIVISIONSR epublic Paperboard Company the world s first Paper machine with two gap formers2 Stock Preparation: Wet End process New Technology solutions around the Paper machine wet end7 Stock Preparation: Screening of recovered Paper stockfor the production of graphic papers12 Paper Machines: DuoFormer TQv a new twin wire former 17 Paper Machines: DuoCleaner the optimal fabric and felt cleaning system22 Paper Machines: Kehl PM 6 a new production line for laminating papers 26 Paper Machines: Dongying Huatai successful start up30 Paper Machines: Zhuhai BM 2 started up 2 weeks ahead of schedule32 Paper Machines: Bauernfeind PM 1 strengthening of Frohnleiten mill36 Paper Machines: TissueFlex first application in America 40 Paper Machines: Sirius the online wind-up system 42 Finishing: A look behind the scenes preparations for the start-up of the Janus MK 2 for Schongau PM 945 Service.

2 Partnership with papermaker leads to innovative solution49 Paper Machines: process Technology meeting current and future demands on system suppliers52 CORPORATE NEWSV oith S o Paulo, Brazil55 Stickies summit in Washington, CULTURE Festas do Povo , Campo Maior60 Frontispiece: Republic Paperboard Company the first parent rolls produced on the new machine with two gap Customer, dear Reader,We have pleasure in introducing you to Issue No. 10 of our popular twogether PaperTechnology Journal for the pulp and Paper industry. The positive feedback we continueto receive from around the world encourages us to keep up the high standard ofarticles published in this truly international communications tool.

3 We are fully aware that the consolidation trend among our customers has not ceasedand this continues to have a damping effect on worldwide order placement for com-plete new production lines, particularly in the graphic papers section. On the otherhand, demand for rebuilds aimed at product quality improvements, especially for finish-ing equipment, remains buoyant. Our Board and Packaging Paper operations also showa healthy level of activity, pointing to a record booking level for the current businessyear. Similarly, we can see positive trends in demand for our stock preparationproduct lines. In the meantime, our leading position in shoe press Technology has been furthersubstantiated with the order for the 200th NipcoFlex Shoe Press since market intro-duction of this innovative second calender generation of our Janus Concept line Mark II , has beensuccessfully introduced to the Paper industry and the performance of our Janus tech-nology in Port Hawkesbury, Canada, has been stabilized, providing a significant contri-bution to the record-breaking production levels for SC-A grades on PM 2 at this mill.

4 Successful integration of the Scapa Plc roll covering line into our Service Divisionconfirms the merits of this decision to add to the overall competence of our systemsupplier approach. Our customers likewise benefit from the close link betweenVoith Fabrics (now incorporating the complete range of Scapa s fabrics activities) andVoith Sulzer s development of new Paper machine processes and components. In short, we see an exciting time ahead of us and we have full confidence in the con-tinueing fine performance of the industry we serve. Yours sincerely,Hans M lleron behalf of the Voith Sulzer Paper Technology TeamHans M ller,President and CEOV oith Sulzer Paper Technology2 The author:Christoph Merckens, Paper MachinesBoard and PackagingRepublic Paperboard Company the world s first Paper machine withtwo gap formersThe Republic Group Incorporated a company looking to the futureHeadquartered in Hutchinson, Kansas,Republic Group Incorporated (NYSE:RGC), the parent Company of RepublicPaperboard Company, is comprised ofthree business segments, namely Paper -board manufacturing, gypsum wallboardmanufacturing and Paper recycling.

5 Theproduction of gypsum-grade paperboardand gypsum wallboard has always beenOn November 27, 1999, RepublicPaperboard Company, Lawton,Oklahoma, USA, brought about arevolution in Paper manufacturing: A new gypsum-grade paperboardmachine was brought on-line the world s first Paper machine with two gap formers. This milestone inboard and packaging Paper productionillustrates the technological leadershipand innovative spirit of Voith SulzerPaper in the USA. To achieve thisgoal, they were interested in new, innova-tive technologies, some of which were al-ready being used successfully in , Oklahoma was chosen as the siteof the Paper mill due to its central loca-tion in relation to both Republic s internaland external customers.

6 A large part ofthe production is sold to other domesticgypsum wallboard manufacturers throughlong-term delivery paperboard as a productGypsum wallboard is made of a gypsumcore and two sheets of Paper , accountingfor both strength and appearance of thewallboard. The two-component creamface(white top layer and gray filler) is usedfor the face of the gypsum wallboard;whereas, one-component gray board isused for the back (grayback). Both prod-ucts can be manufactured on Lawton sPM 1. The requirements to be met by bothgrades are complex; however, the mostdecisive properties are high strength, ahydrophobic top layer (achieved by siz-ing) to shield the product against humid-ity from outside and a hydrophilic backlayer to achieve optimum bonding be-tween gypsum and paperboard.

7 Current-ly, basis weights range between 190 g/m2(39 lbs/MSF) and 200 g/m2(41 lbs/MSF),but are to be reduced to 180 g/m2(37 lbs/MSF) in the years to come. Apartfrom the two gypsum-grade paperboardproducts, the mill can produce a varietyof other products. The machine is de-signed to produce basis weights from127 to 244 g/m2(26 to 50 lbs/MSF). An ambitious project is taking its courseRepublic Paperboard s vision was clearlydefined right from the start to doublecore businesses of Republic. To offergypsum-grade paperboard also in thelower basis weight range, it was decidedto supplement the Company s paperboardmills located in Hutchinson, Kansas;Commerce City Denver, Colorado; andHalltown, West Virginia, with a newgreenfield paperboard mill.

8 In a press re-lease, Phil Simpson, Republic's Chairmanand President, declared that the grouphad set a goal to become a leading manu-facturer of lightweight gypsum-grade pa-Fig. 1 and 2: Republic Paperboard Company inLawton, Oklahoma, group s Paper production with a new,high quality, low cost production the summer of 1997, Voith Sulzer wascontacted as one of several renownedsuppliers to work on a project for themanufacture of three or four-layer gyp-sum-grade paperboard. One of the cus-tomer's basic requirements was to useonly components that had already beentried and tested. Therefore, a design withthree fourdrinier wires was developed forthe wire section, which was being testedon the Voith Sulzer test Paper machineStock preparationThe stock preparation system was deliv-ered and started up by Voith Sulzer PaperTechnology, Appleton, Wisconsin, USA.

9 Itconsists of two lines, one for the whitetop layer of the creamface and anotherone for the gray filler and backlayers ofcreamface and all layers of the 3: Pulper in the stock 4: Scheme KM 5: Final section of 6: DuoFormer Top with board and packaging papers atRavensburg, Germany. At the same time, the Voith Sulzer projectteam presented a configuration with thetwo gap formers especially developed forboard and packaging papers, Duo-Former Base and DuoFormer Top,which seemed to be ideally suited for theproduction of gypsum-grade gap formers were installed on thetest Paper machine at the time when thetests for the fourdrinier wire design wereperformed.

10 The customer became inter-ested in running tests with the gap form-ers as well, which then prompted anotherseries of tests. These extensive field testsdetermined that fitting the new machinewith gap formers was the correct dedicated teamwork of RepublicPaperboard and the Voith Sulzer teamhelped to create the trendsetting designfor the world s first Paper machine withtwo gap February 19, 1998, Voith Sulzer PaperTechnology finally obtained the order todeliver two complete stock preparationlines, the Paper machine and a achieve excellent results in slushingand cleaning of the recycled Paper , thedesign for both lines was developed inclose cooperation with the customer andon the basis of tests performed atRavensburg, Germany, and Appleton, white line is fed with primarily un-printed white grades of Paper and has acapacity of 240 tons/day.