10 ■ PAPER INDUSTRY ■ June 2006

Dual ruby orfice

nozzle gives precise,

clean cuts in paper

trimming applicationsThe UltraStream®

nozzle fromSpraying SystemsCo. has a powerful,needle-like solidstream spray thatdelivers preciseedge trimming, cutting and slitting. Thetwin parallel sprays are excellent for trim-ming fine or specialty papers.

The dual orifice design eliminates theneed for two nozzles and simplifies sprayalignment. The beveled body directssplash-back to the waste side of the trimand reduces build-up. The synthetic rubyorifice creates a more precise stream andlasts longer than stainless steel or ceramicorifices. Even in early stages of wear, theruby orifice maintains a steady solidstream spray pattern.www.spray.com

FastInfo #158

Solve unevencoating challengeswith a customspray headerWhen uniformcoverage is crit-ical, SprayingSystems Co.can custom fab-ricate a sprayheader to meetyour exact specifications. A custom sprayheader is an effective solution in chemicalcoating and moisturizing applicationswhere uneven coverage across the contactarea is a typical problem. Features that canbe customized include:• Nozzle spacing and spray pattern overlap• Nozzle distance to target• Lengths, pipe sizes and inlet connections

to meet physical space limitations• Air atomizing nozzles for independent

control of liquid and air• Hot water recirculation systems that

keep moisturizers at a consistent temper-ature

• Self-cleaning models that eliminatedowntime by cleaning without processinterruption

• Oscillating or fixed headers• Enclosed box styles to protect nozzles

and connections from debrisSpraying Systems Co. manufacturingprocesses are ISO 9001:14001 certified.They can provide complete material trace-ability and conduct performance testing toANSI and ASTM standards.www.spray.com

FastInfo #159

S p ray i n gS y s t e m sCo. offers ar e t r o fi tmotor andc o n t r o lunit toautomate

your existing manual brush shower. An internalrotating brush scrubs the interior wall of the showerand nozzles without disrupting production. The

retrofit kit allows you to activate the shower clean-ing cycle at the push of a button, or optional timingcontrol can completely automate the cleaningprocess. Simply remove the handwheel from yourexisting brush shower and install the Smart Motor.It eliminates the need to have workers climbingmachines to rotate handwheels and is ideal for millswith a low personnel count.www.spray.com

FastInfo #157

Paper is unyielding.When there is no room for error,the process has to be right.

Spray technology for flawless operations.Spraying Systems Co. understands how critical spray operations are to the paper industry. Our comprehensive knowledge of spraytechnology will help you implement improvements at each stage of your production cycle.

Only Spraying Systems Co. has the vast array of products and services that offer:

• Spray nozzles and products for every area of your mill

• Insight into the unique needs of paper manufacturing

• Advanced spray analysis and testing services

• Specialized prototyping and fabricating

• Spray automation for better control

Our knowledge of paper and spray technology delivers the resources you need for a flawless operation.

Call us today for a FREE evaluation of your spray operation.

1-800-95-SPRAY www.spray.com

Experts in Spray Technology

SprayNozzles

SprayControl

SprayAnalysis

SprayFabrication

Quickly and cost-effectively cleanclogged nozzles in shower headers

ADVERTISEMENT

FastInfo #106

June 2006 ■ PAPER INDUSTRY ■ 11

Catalyst Paper, Vancouver, BC, producesmechanical printing papers, de-inkednewsprint, market kraft pulp and con-tainerboard. With five mills employingabout 3,800 people at sites within 100miles of each other on the south coast ofBritish Columbia, Catalyst has a com-bined capacity of 2.5 million tonnes/yearof product.

The Situation. Catalyst Paper neededbusiness improvement opportunities tomaintain both profitability and industryleadership. With billions invested in itsfour paper mills, improved performancewould be key to long-term profitability.

Partnering with Ivara Corporation,Burlington, ON, Catalyst embarked on areliability improvement program. Thegoal was to increase the effectiveness ofthe maintenance and operations func-tions in optimizing asset reliability todrive a capacity increase of as much as3%, as measured through paper machineefficiency.

The Challenge. Catalyst needed toaddress several challenges: Ensure collab-

oration among employees; managechange; secure internal support for theproject; retain equipment knowledge thatcould be lost as experienced operationsand maintenance workers retired.

Also, Catalyst had to show that a reli-ability-based culture involved more thana quick technology fix; it would involve achange in the way maintenance andoperations employees worked.

The Solution. Catalyst Paper chosethe Ivara Reliability Solution as itsapproach to improve mill performance.The Ivara Work Smart methodologyaligned well with Catalyst’s core value ofinvolvement and addressed the need foreffective change management.

The process began with a two-daystrategy workshop for more than 130employees from all levels of management,engineering, maintenance and opera-tions, including both unionized and non-unionized employees.

The workshop achieved a consensuson the strategy and cemented the visionand direction the reliability initiative

would take. It also showed that previousinvestments to improve plant operationsand maintenance could be better lever-aged under Ivara’s pro-active businessprocess for reliability.

Next, Catalyst assembled a multi-millreliability team to do a detailed reliabilityassessment and business case at eachmill, and then create the financial impactplan. The Port Alberni mill was first toadopt the new strategy. The financialimpact plan laid out the roadmap toachieving the 3% increase in paper-machine efficiency.

A core team of Port Alberni employeeswas established comprising a dedicatedcross-section of five employees frommaintenance, operations and engineer-ing. Ivara facilitated workshops for thefour mills to map out the asset reliabilityprocess and determine roles and respon-sibilities.

Ivara trained and coached the group: Ithelped to prioritize assets, system-by-sys-tem, according to consequence and rela-tive risk to the business. Ivara also helpedthe core team to develop asset reliabilityprograms using its work identificationpractice, Maintenance Task Analysis.Ivara worked with trades and operatorsto ensure the new reliability process isimplemented and sustained within eacharea.

The Result. The Ivara approach isenabling Catalyst to adjust and augmentexisting processes, practices and tech-nologies to optimize the reliability andperformance of plant assets. Ensuringthat the right work is being done on theright equipment at the right time,Catalyst is moving to the next level inoperational effectiveness. As the pro-gram progresses, the benefits of Ivara’sasset reliability process are being real-ized:

• The collaborative nature of the Ivaraprocess has created strong internal sup-port – a critical success factor.

• The extensive equipment knowledgeamong the employees is being trans-formed into business change.

• Maintenance and operations areworking together consistently to developand implement the new reliabilityprocess.

• Improving asset reliability is nolonger viewed solely as a maintenanceresponsibility but one that is sharedamongst maintenance, operations andengineering.

• A single, comprehensive reliabilitybusiness process — developed and agreedupon for use in all four mills – supportsCatalyst’s desire to standardize businessprocesses.

• The experience and knowledge ofequipment experts is not lost upon theirretirement.

Conclusion. At Port Alberni aloneincreased capacity and cost savings total-ing $1.5 million are anticipated in yearone and expected to reach $7.1 millionper year after the three-year ramp-up. PIIvara Corp., www.ivara.com

FastInfo #205

I s s u e H i g h l i g h t – S o f t w a r eCatalyst adopts Ivara process to improvemill performance by up to 3%

Liaison Technologies, Alpharetta, GA,a real-time B2B infrastructure provider,says it has implemented its EnterpriseContent Director for coated-paper pro-ducer NewPage Corp. EnterpriseContent Director is for product infor-mation management (PIM) and roundsout the NewPage master data manage-ment strategy.

Moving from infrequent to weeklyproduct information updates,NewPage’s e-commerce group canintroduce new products faster and pro-vide richer product information formore than five million unique items.NewPage’s four pulp and paper millshave a capacity of about 2.2 milliontons/year of coated papers.

Liaison’s Enterprise ContentDirector is a managed service synchro-nized with NewPage’s SAP enterprise

resource planning (ERP) system. Builtto transform disparate data systemsinto a single master representation ofsystem data, Liaison’s PIM combinescustomizable workflows with a valida-tion engine and active data repository.

Liaison says it operates the world’slargest papiNet XML hub and its man-aged services enable more than two mil-lion XML-based, real-time transactionsper month. Until April 2004, Liaisonwas known as ForestExpress, an indus-try trading exchange for papermakers.Customers include International Paper,Weyerhaeuser Company, Merck & Co.,PaperlinX, MAP, Lecta Group, M-Real,Sappi, Stora Enso, Grupo PortucelSoporcel and Unisource. PILiaison Technologies, www.liaison.com

FastInfo #203

Liaison Technologies boostsNewPage e-commerce

Panther’sMillToolsadvanceproduction,quality controlPanther Systems, Inc., Vancouver,WA is a specialist solutionsprovider in the pulp and paperindustry.

MillTools, Panther’s applica-tion portfolio, covers every aspectof the production process from pro-duction to quality to the frontoffice. MillTools provides real-time production data for single ormulti-machine paper mills. In addi-tion to addressing front office andproduction needs, MillTools caninclude TestCentral, Process-Analyzer and ICIS.

TestCentral tracks paper quali-ty by reel, sets, and rolls.TestCentral consolidates all testresults from test labs and scannermeasurement profiles. Panther hasautomated interfaces for bench topinstruments and multi-test devices.Back-tenders and machine tendershave web access to real-time tur-nup and test information enablingoperators to make quick machineadjustments to meet customerspecifications and eliminate waste.

ProcessAnalyzer is a perform-ance tool for Profile analysis. It pro-vides managers, engineers, techni-cians and operators with the capa-bility to quickly determine thecause and effect of production qual-ity issues. ProcessAnalyzerenables the evaluation of machineperformance for those quality andprocess problems that affect milloperation and efficiency.

ICIS, Panther’s QCS, providesadvanced features that enhance theproduction control of papermachines by integrating keymachine variables from wet-endstock control to dry-end qualitysensors and scanners. AdvancedMD control algorithms performpredictive mathematicalmaterial/energy balance for overallproduction improvements.Integrated CD control providesimproved sheet quality. ICIS hasreplaced every major QCS systemon the market, providing customerswith a lower cost solution thatdelivers quality results and signifi-cant investment returns.

Panther’s MillTools and Test-Central dynamically connect toPanther’s ICIS Quality ControlSystem (QCS) and other third-party control systems. Panthersolutions are installed in 25 USmills ? with the same code base inevery mill. PIsales@panthersys.com, www.pan-thersys.com

FastInfo #206

Emerson Process Management, Austin,TX, has enhanced its DeltaV™ systemsoftware with the release of version 8.4software. It includes easier access to his-torical data, easier data backup and anenhanced operator interface. Operatorscan now more quickly access keyprocess parameters and respond morequickly to ongoing operational needs.

Dave Deitz, director of marketingfor the DeltaV system, said the releaselets “operators view historical trendsdirectly in the DeltaV Operate viewhelping them make better decisions.”The operating console now has a four-

monitor workstation with more screen“real estate” so operators can view face-plates, trends and other windows,without blocking their primary controlgraphics. The console can now have acompletely configurable operator key-board for faster operator response.

The release also provides for eitherscheduled or automated real-time databackups to historical database applica-tions improving data integrity. PIEmerson Process Management,www.EasyDeltaV.com/version84.

FastInfo #204

Emerson enhances DeltaVfor precise control

Apriso® Corp. Long Beach, CA has announcedFlexNet® for Mill Products, software to help millsoperate more profitably and with greater agility.FlexNet is designed to help control the costs of energy,raw materials, machine maintenance, labor, qualityassurance and constantly changing business drivers.

Apriso says FlexNet incorporates OSIsoft andGreycon capabilities to replace monolithic, paper-based systems with an adaptive operations executionplatform. The solution is suited to both primary andconversion operations in the pulp and paper industry,says Apriso.

FlexNet manages a number of areas on a singlesoftware platform built on a unified data model. Itprovides complete visibility into areas such as work-in-progress, raw materials and maintenance so thatpersonnel can make timely decisions and take fastcorrective action when needed.

• Energy efficiency — FlexNet provides 100% vis-ibility into equipment use to permit efficient alloca-tion of energy resources;

• Quality assurance — FlexNet integrates qualityprocesses into its Production module enabling milloperators to “make it right the first time”;

• Inventory visibility — Complete supplier visibil-ity lets FlexNet identify possible supplier shortages intime to find other sources of materials;

• Adaptability to change – FlexNet lets mill operatorschange production processes to meet shifting customerspecifications in a matter of hours, without enlistingoutside IT support or bringing their systems down.

FlexNet is both an adaptive operations executionplatform and a suite of software modules that tietogether production (MES), warehouse (WMS), qual-ity (QMS), maintenance, time and labor, and suppliervisibility. Working with other technology partners,Apriso’s software supports specific requirements suchas capacity planning, trim optimization, production

control, quality data management, converting, ware-housing and shipping.

FlexNet integrates with SAP, Oracle and other lead-ing enterprise systems with little to no overlap. InDecember 2005 Apriso achieved “Powered by SAPNetWeaver® for Industry Standards” status, one of onlya handful of vendors to do so in the MES space.

FlexNet offers high scalability and can be installedeither as individual modules or as a suite. It incorporatesX-Trim®, Greycon’s trim optimization system, andOSIsoft’s PI System, a productivity resource giving oper-ational visibility.

Apriso says that FlexNet is the first business processmanagement/service-oriented architecture (BPM/SOA)solution for mill operations and meets the growingdemand for manufacturing software systems incorporat-ing BPM functionality. Process Builder™ is a drag-and-drop interface tool for customers to do their own recon-figurations, authoring Web-enabled electronic “flows” tointernal workstations or to the corporate enterprise – allwithout coding. PIApriso Corporation, www.apriso.com.

FastInfo #207

Apriso’s FlexNet for Mill Products now available

12 ■ PAPER INDUSTRY ■ June 2006

I s s u e H i g h l i g h t – S o f t w a r e

FastInfo #107

Anson Bearings have superior life and serviceabilitywithout compromising economy

Visit Our Web Site !www.ansonindustrial.com

Anson Bearings have superior life and serviceabilitywithout compromising economy

Visit Our Web Site !www.ansonindustrial.com

1-800-663-77231-800-663-7723

USED IN:LOGDECKS, LOG STOPS, UNLOADERS,

KICKERS, HOUR GLASS ROLLS,DEBARKERS, ETC.

USED IN:LOGDECKS, LOG STOPS, UNLOADERS,

KICKERS, HOUR GLASS ROLLS,DEBARKERS, ETC.

PULP &PAPER

EQUIPMENT

Sprockets,

Drag, Custom

and Logging Chains,

Take-up Frames,

& Bearings

Sprockets,

Drag, Custom

and Logging Chains,

Take-up Frames,

& Bearings

FullCatalogue

on theInternet!

Tel: [604] 952-4055Fax: [604] 952-4058

TietoEnator TIPS trimoptimizer and FreightCalcnow SAP certified TietoEnator Corp.’s Integrated Paper Solutions(TIPS) Trim version 12.1 is now certified for inte-gration with the mySAP™ Supply ChainManagement (SCM) application Release 4.0. Thecertification helps ensure the smooth flow of infor-mation between mySAP SCM and TIPS Trim forstatus checking, optimization, trim sheet order pro-cessing and performance load testing.

TietoEnator says that, if no previous optimizationhas been done, TIPS Trim together with integratedplanning and production management, has helpedcustomers to reduce trim loss about 2 to 4% annual-ly. Even replacing an old optimization package canreduce trim waste a further 1/2 to over 2% annually,depending on the mill, paper grades or order backlog.

TIPS Trim can be fully integrated with the TIPSproduct family, a comprehensive sales and produc-tion management tool for the pulp and paper indus-tries. It can also be integrated with any third-partysystem. TIPS Trim benefits include increasedmachine capacity, reduced material costs and on-time planning without delays, says the company.

• As well, TietoEnator’s FreightCalc freight costmanagement solution, developed initially for Sappi,has received “Powered by SAP NetWeaver®” certifi-cation. FreightCalc is part of a warehouse manage-ment solution TietoEnator has developed togetherwith Sappi, the world’s largest producer of coatedfine paper. Sappi uses FreightCalc at its Europeandistribution centers to manage global transport. PITietoEnator Corp., www.tietoenator.com

FastInfo #208

work to automate invoice delivery to assure fullline-item detail and 100% data accuracy in the pro-cessing systems.

OB10 says its system can reduce the cost of man-ually processing invoices by as much as 80% withan ROI of under six months. Other benefits include:compliance with regulatory requirements includingSarbanes-Oxley and VAT; invoice format “agnosti-cism”; no new hardware or software required ateither invoice sender or receiver sites; dedicatedservice teams to help newly-enrolled suppliersadapt to the OB10 network. PIOB10, www.ob10.com

FastInfo #209

FKI Logistex upgradesOrder Manager

FKI Logistex®, St. Louis, MO, has upgraded itsOrder Manager™ software solution — a combinedwarehouse management system/warehouse controlsystem (WMS/WCS). Upgrades include RFID sup-port, enhanced order management, inventory con-trol and productivity reporting.

Order Manager is designed for both small, man-ual stockrooms and warehouses requiring an auto-mated equipment interface with a short implemen-tation time and eliminates the need for multipleconnections to a company’s enterprise business sys-tems (EBS), says the company. An EBS can com-municate with Order Manager directly, avoidingmultiple hardware and software vendor connec-tions.

Designed as a set of interlocking modules thatcan be turned on and off as required, OrderManager tailors the application to the customer’sneeds. Order Manager complements the WarehouseOptimizer™ VNA storage-and-retrieval system soft-ware, EASYpick® order fulfillment software and thecomplete line of FKI Logistex software solutions formanufacturing, warehouse and distribution centerenvironments. PIFKI Logistex, www.fkilogistex.com

FastInfo #210

June 2006 ■ PAPER INDUSTRY ■ 13

I s s u e H i g h l i g h t – S o f t w a r e

To ensure accuracy and trim expenses of the complexinvoice-to-pay process, industrial packaging productsand services company Greif has signed a five-yearservices agreement with OB10, a San Francisco, CA-based supplier of B2B e-invoicing delivery solutions.

Under the agreement, thousands of Greif’s suppli-ers will stop sending paper invoices and move to elec-tronic delivery via the OB10 global e-invoicing net-work which has members in 70 countries and acrosssix continents.

Greif, a $2.4-billion corporation, operates threebusiness groups, namely Industrial Packaging and

Services, Paper, Packaging and Services, and Timber.It has 160 locations in over 40 countries, producingcontainers and containerboard for bulk shippers inthe chemical, food, petroleum and pharmaceuticalindustries. Greif manages timberland operations inthe US and Canada.

Greif had been using OCR, workflow and Baan sys-tems to manage its A/P and invoice-to-pay processes.Inaccuracy resulted in errors such as paying thewrong vendor and/or wrong dollar amounts. After atwo-year search, Greif cancelled the OCR licensingagreement and selected OB10’s global e-invoicing net-

Greif signs for e-invoicing services with OB10

FastInfo #107

Superior Quality Control to Ensure You Get the Best

ProtectedGreaseNipple

Grade 5Bolts

Keyway

SquareNuts

MachinedBottom

FabricatedSteel Base

ExclusiveEasy toReplaceRoll-outShells

Industrial Manufacturing Corporation7392 Progress Place

Delta, British Columbia,CANADA, V4G 1A1

AngleBearings

FlangeBearings

2500 Super Bearing SeriesThe Famous ORIGINAL

2500 Series Super BearingsIndustry Standard for 20 Years

2500 Super Bearing Series

To obtain product information see

Reader InquiryCard Service

Page 35

14 ■ PAPER INDUSTRY ■ June 2006

FastInfo #108

CAN-AM CHAINS

Engineered PlasticsCan-Am Plastics — A full range of engineered plastics for the forest products industry.

— CHANNEX, UHMW, NYLONS and URETHANE COMPONENTS.

+ Noise & Vibration Dampening Engineered Plastics

Welded Steel Mill Chain

Wear-Guardcustom-engineered UHMW

Two integral layers of polymer mouldedtogether in two contrasting colors.

The bottom layer is a wear indicator.

CAN-AM ICE

High performance wear material designedfor high load, and tough abrasive

applications. The mechanical propertiesof CAN-AM “ICE” have been modified

to increase its hardness and dimensionalstability. Ideal for heavy Mill and Drag chain

wear plate applications.

ENDURAEXTREME DUTY

High performance Engineered Plastic developed for high-speed roller and sharp chain applications.

Sprockets, Sleeve Bearings& Chain Accessorieswww.can-amchains.com

Sold & Serviced throughout North America:USA

Clackamas, OR Spokane, WA Shreveport, LA Birmingham, AL Rocky Mount, NC800-547-6274 800-827-1524 800-321-8846 800-824-0674 800-856-0744

CanadaSurrey, BC Prince George, BC Edmonton, AB New Liskeard, ON Quebec

604-599-1522 250-562-7727 780-955-3993 705-647-5366 418-681-3846

Magnetic wear platefastening systemfrom Can-Am ChainsMagna-Plate™ is a highly efficient method ofwear plate attachment. This product combinespowerful magnetic elements in flexible elas-tomeric compounds. Magna-Plate™ offers aquick, clean and safe method to attach wearplate.

Magna-Plate is available in three models:standard, high impact and wet application.

Features of the Magna-Plate system includemaintenance free permanent magnetic power,fast change out (eliminating welding, gougingand grinding), prevention of weld crystaliza-tion, noise and vibration dampening.

Custom designs are available to meet specif-ic applications.Can-Am Chains, www.can-amchains.com

FastInfo #160

NH78 Plastic Chainfor corrosive usesNH78 Plastic Chain is an acetal chain for usein non-marking and corrosive applications. Anexcellent alternative to conventional steel 78chain that can be used around dip tanks, fin-ished product and sewage treatment.Can-Am Chains, www.can-amchains.com

FastInfo #161

Can-Am Chains, Surrey, BC, has intro-duced Magna-Patch™, a reusable magneticpatch. This highly visible product is a quickand secure means of repairing holes in steelpipes, flat back elbows, round radiuselbows, silos, chutes, hoppers and othersteel applications susceptible to abrasion.Magna-Patch combines magnetic elementsin flexible elastomeric material.

Designed to reduce downtime, materialloss and cleanup costs associated with high-ly abrasive conveying systems, Magna-Patch functions equally well in pneumatic

conveying, gravity feed and slurry pipingsystems. Magna-Patch benefits include easyapplication, increased up-time, mainte-nance free, high visibility, re-usable,reduced product damage, reduced productloss.

Magna-Patch is simply positioned overthe worn out area and is securely held inplace magnetically until the next scheduledshut down.Can-Am Chains, www.can-amchains.com

FastInfo #162

Can-Am offers Magna-Patch™ areusable magnetically fastened patch

ADVERTISEMENT

NEW

June 2006 ■ PAPER INDUSTRY ■ 15

An instrument to measure thewater content of press felts,the L&W Felt Moisture Meter,had its world premiere at theAsian Paper Exhibition inBangkok, May 10-12.

Lorentzen & Wettre saysthe L&W Felt Moisture Meteris the sixth generation instru-ment for profile measurementsof the water content of press

felts using microwave technol-ogy originally develop byScanpro. Nearly 40 years ofexperience and developmenthave gone into the instrument,which combines advancedfunctionality with usability.

Correct handling of thepress felts results in longerlife and lower expenses. Toachieve this, it’s important to

measure the felt’s quality andto find weak points in thepress section. The measure-ment results help paper pro-ducers to take the right actionat the right time. A new PC-software, L&W Multiview3D, can display three-dimen-sional images of water varia-tions in felts including fre-quency analysis of machinedirectional data and reportfelt length.

Regular measurementswith the moisture meter arethe key to optimal dewateringin the press section and lead tofewer problems with machinedisturbances and downtime,says L&W.

The meter is held by handin contact with the felt andmanually scanned across thewidth of the web. The scanrate is 1000 times/sec and themeasurement area is 40x40mm to give high resolutionand detailed information

about moisture variations.The measurements are firststored in the instrument andthen transferred to a PC with ahigh-speed USB connection.

L&W has added two func-tions to the instrument. Thefirst is an optical “trade linedetector” which synchronizesthe measurements in the MD.Also new is an ultrasonic tech-nique to measure the actualmeasuring position in the CD.

These two techniques makeit possible to display the feltmoisture variations in a PC astwo- and three-dimensionalgraphs of a felt which L&Wclaims is absolutely new in theindustry.

By measuring the felt’s watercontent, before and after thepress, dewatering can be opti-mized. Effective dewatering inthe press section can reduceenergy consumption in thedryer section and increase pro-duction considerably; a 1%

increase of dry content in thepress section gives a 4% reduc-tion in energy use in the dryer.To optimize dewatering, actionshould be taken in the press sec-tion to avoid additional energycosts in the dryer section.

“A paper machine standingidle is expensive; a large papermachine not producing cancost in the order of Euro20,000 per hour.” says LarsKånge, product manager ofL&W Felt Moisture Meter. “Atwo-hour per year reduction inunplanned machine downtimecould mean that the invest-ment in an L&W Felt MoistureMeter has paid for itself,” saysKånge.

The moisture meter, acces-sories and the L&WMultiview 3D PC software areincluded in the package. PIAB Lorentzen & Wettre, www.lorentzen-wettre.com

FastInfo #211

I s s u e H i g h l i g h t – M a c h i n e C l o t h i n gL&W felt moisture meter can reduce production costs

Vibre-Tech LLC, Little Chute, WI, saysits RotoSweep™ is designed to keepdryer fabrics clean and porous toimprove drying efficiency.

A rotating brush mounted on a trol-ley traverses the width of the fabriceither continuously or intermittently.It is situated radially along the axis of afelt roll where contaminants are par-tially lifted from the fabric.

The brush itself is cleaned throughthe centrifugal action of its rotation.The contaminants are expelled into acollection pan or accumulated with anoptional vacuum system.

The brush and traversing mecha-nism are driven by electric motors.When not in operation the brush canbe retracted away from the fabric by anair cylinder.

Results from Vibre-Tech studiesshow reduced steam consumption.Dryer steam use was monitored over15 days. The fabric was cleaned afterthree, five and seven days resulting inan immediate drop in steam consump-tion. In the same series of tests, Vibre-Tech also found improved CD moistureprofile.

Among other benefits, Vibre-techespecially notes improved safety foroperators who do not have to handlechemicals or scrapers. Maintenancecosts are low because there are no noz-zles, pumps or filters. There are fewersheet breaks, no sheet re-wetting and nocontaminant discharge to the sewer. PIVibre-Tech LLC, www.vibretech.com

FastInfo #212

Vibre-Tech RotoSweep keeps dryer fabrics clean

Albany International Corp., Albany,NY, has introduced its Aeropulse™described as a new concept in dryerfabrics; it uses flat monofilament yarnsin both the MD and, at the backside,the CD.

The combination of the uniquebackside with tilted flat monofilamentsand very smooth paper-side providesimproved heat transfer, active ventila-tion and evaporation through the fab-ric, and reduced humidity levels in the

boundary layer, resulting in more effi-cient drying, says the company.

Aeropulse’s 100% flat monofilamentkeeps cleaner and is easier to clean,says Albany. The double density con-struction gives uniformity, smoothnessand strength, and ensures easy seam-ing. PIAlbany International, Corp.,www.albint.com

FastInfo #214

Huytexx says its Synergie is a super-fine, plain weave paper surface fabricthat offers ultra high fiber support atany given permeability.

It has a 2:1 paper side to machineside CMD yarn ratio. The machine sideis a five-harness. Synergie offers fineMD and CMD yarns to promotereduced caliper and void volume withthe purpose of improving off-couchconsistency. The standard product con-sists of nylon binders as well as nylonpick & pick machine side yarns forincreased life potential.

According to Huytexx, Synergie’sproduct strengths include: Its

patented structure; the low caliperand void volume; increased reten-tion; reduced chemical costs; highercouch solids.

Synergie also offers improved two-sidedness, formation, filler distribu-tion, porosity and sheet strength.Cleaner running and good life potentialare other attributes, says Huytexx.

Applications for Synergie fabricsinclude fourdriniers, hybrid formers,newsprint and fine-paper gap formers,and LWC and SC hybrid formers. PIWeavexx, www.weavexx.com

FastInfo #213

Albany Aeropulseimproves heat transfer

Huytexx says Synergie is super-fine

New Generation MaierHW Rotary Joints

Maier America, Norcross, GA hasintroduced a new generation of faster,more robust and flexible HW RotaryJoints particularly suitable for applica-tions involving liquids like water andthermal oil, as well as for steam.

New design improvements which

enable up to 50% higher speedsinclude an anti-rotation device betweenthe bearings ensuring low moment offriction; greater distance between bear-ings and double sized cover bushing.They also feature a gasket sealed hous-ing flange connection so no soldering isrequired.

The HW Series is also a modularsystem where the required position canbe specified with order and housingflanges can be screwed in later.

All steel parts are in stainless steeland rotors made of grade 1.4571 stain-less. The HW Series Rotary Joints aremaintenance free and no relubricationis required. PIMaier America,www.maieramerica.com

FastInfo #215

16 ■ PAPER INDUSTRY ■ June 2006

Pacific Saw & Knife, a long time leader in doctor blades,ceramic blades and wood products, is introducing a com-plete line of doctor related products to complement it’salready aggressive line. The doctors products line will bea complete line including creping, former, center pressand double doctors.

Our line will include P-DST blade holders, P-K35holders, P-DST double and single plated holders. P-CREPING doctors holders in three different styles.

Equipment line will include bearings, cylinders, turn-buckles, P-DST tubes, P-Viton tubes, P-HD CF backingblades, P-HD CF tubes, oscillators (air, water andmechanical).

The Pacific International staff will design, engineer,service and install all products to each customer’s cus-tom specifications.

All doctors will be followed up by a staff that has over

New Pacific doctor and double doctor systems and bladesADVERTISEMENT

55 years in the design, sales, service and instal-lation field.Pacific International, www.pacificintnl.com

FastInfo #163

FastInfo #109

Breakthroughtechnology forCreping BladesPacific International Perma-Life creping bladesoffer up to 10 time the life of a traditional steelblade – with less Yankee wear, meaning fewerYankee regrinds.

Other results show that when using virginpulp in tissue paper stock use of a spray coat-

ing significantly improves the Pacific Perma-Life blades performance.

When using recylced paper, the hemicellu-lose contained in the stock may not require theuse of the spray coating, whereas the Perma-Life blades will still perform to specification.Due to the fact the Perma-Life blade cleans theYankee better than a steel blade, the use ofcleaning blades may not be necessary. Due tothe extreme smoothness of the Perma-Life cre-ping blades, Pacific says they will maintainpaper quality even when gaining bulk.www.pacificintnl.com

FastInfo #164

Ceramic edgedCoater BladesNew LLC Perma-Life Coaterbaldes fromP a c i f i cInternational aredesigned to offerincreased hard-ness and bettersmoothness with a new modified ceramic edgeresulting in higher precision, increased pro-duction capacity and updated quality control.

These Pacific Coater blades are producedfrom the finest blue polished spring steel withsuperior straightness and precise steel uniformbevels which range from 0 to 90 degrees. Theselong lasting blades require minimum break intime and produce an even coating whichresults in increased production and reduceddowntime.

Pacific also has stainless coater rods withspecial hard chrome coating with tolerances of+.06-0” (1.6mm - 0mm) on the length and+/- .001 (.0254mm) on the diameter. This pre-cision means superior wear, running qualityand coating performance.Pacific International, www.pacificintnl.com

FastInfo #165

See us atZellchemingat Booth#958

June 2006 ■ PAPER INDUSTRY ■ 17

Sheet-breaks are a significant contrib-utor to lost paper machine efficiency,productivity and greater operatingcosts. Consequently, sheet breakreduction is a major area of focus formost paper operations.

Like many mills in the industry,PM 7 at Abitibi-Consolidated Inc.’sFort Frances, Ontario, mill sufferedfrom deteriorating production. PM7is a 210-in., 1920’s vintage ValmetBel-Baie III, rebuilt in 1984 and

makes value added communicationspaper. It was running at an average2970 fpm with an average of 2.3wet-end breaks/day and an OverallEquipment Efficiency (OEE) of69.4%. The average downtime for2004 was 75 min/day. In spite ofthe mill’s various improvement ini-tiatives, they could not sustaintheir performance gains and the

benefits gradually decreased overtime.

Solution: “Abitibi was lookingfor a new sustainable method toimprove the paper machine produc-tion,” said Jorg Ruppenstein, processcontrol engineer at Abitibi. “Wewere looking for a quantifiable data-driven approach. This would enableus to compare our performancebefore and after the project, so thatwe could measure a true economicbenefit.”

To solve the problem, Abitibi part-nered with Edmonton, Alberta-basedMatrikon Inc. in a Sheet-BreakReduction Initiative. Abitibi providedall the necessary plant data and oper-ations experience. Matrikon providedthe tools and expertise for theadvanced data mining and analysis.The core technology for this effortwas the Matrikon Process Monitoringsoftware.

The project was broken into fourdistinct phases: Phase 1 Interviewand knowledge discovery; Phase 2Data collection; Phase 3 Data miningand analysis; Phase 4 Definingimprovement projects.

The data analysis used eightmonths’ worth of data stored in themill’s process data historian. The dataincluded information from PM 7’sautomation systems (DCSs, QCSs andPLCs), drives and other sources. Theanalysis enabled the team to classifythe root causes into three majorprocess areas, namely stock prep andstock proportioning, the steam systemand the draw system.

The team found that: 30% of thebreaks were related to changes in thebroke system; 15% of the breaks were

related to dryer section differentialpressure variability along with dryermotor current variability; 15% of thetime, a second sheet break followedthe first within 30 minutes and 15%of the breaks were preceded by largechanges in draws.

The team identified 50 improve-ment opportunities, the top fivebeing:

• Change the broke addition logicand piping from three parallel streamsinto a single stream;

• Repair the dryer controls andinstrumentation;

• Re-commission the white watersilo temperature control system;

• Mechanical repair to eliminatedebris hung up and released after abreak;

• Change the stock proportioninglogic so that broke only displaces

virgin groundwood and not virginkraft.

Results: Since the goal of the proj-ect was to deliver sustainableimprovements, the team calculated allmeasurements over a nine-monthperiod after the project. The resultswere impressive. The average wet-endsheet breaks per day were reduced byover 40% (from 2.30 to 1.36 breaksper day). The average production rateincreased by 12% (from 303 to 338tons/day). Average downtime wasreduced by 37% (from 75 to 47 min-utes per day). OEE increased by 8.3%(from 69.4% to 77.7%).

Benefits: “The Matrikon ProcessMonitoring software helped our FortFrances paper mill realize over $1mil-lion in savings during the first ninemonths alone,” said Ruppenstein.“We have a sustainable, quantifiabledata-driven approach to improvepaper machine production. It wastruly a team effort between opera-tions, engineering, maintenance andMatrikon.”

Abitibi plans to deploy this solu-tion throughout its mills. PIMatrikon Inc., www.matrikon.com

FastInfo #216

I s sue H igh l i gh t – Wet - end Techno logy

The Most ComprehensiveLine of Screw Presses

in the World

Model 24L200 Screw PressApplications:

Stock Thickening Sludge Dewatering:Rejects Dewatering: Primary SludgeKnots & Shives DAF SludgeCoarse & Fine Screen Rejects Mixed Secondary Sludge

PRESS TECHNOLOGY & MFG., INC.1315 Lagonda Ave., Springfield, Ohio USA

Tel: 937 327-0755 • Fax: 937 327-0756Website: www.presstechnology.com

E-mail: dberner@presstechnology.com

FastInfo #110

Case Study

Abitibi, Matrikon solve sheet-break problem

Abitibi-Consolidated’s mill suffered

from deteriorating production over

the years in spite of performance

improvement projects.

Abitibi-Consolidated’s mill suffered

from deteriorating production over

the years in spite of performance

improvement projects.

Vibre-Tech LLC, Little Chute, WI,says its VibreFoil™ enhances stockdrainage and sheet formation byimparting a hydraulic pulse intothe stock from under the formingfabric. It is mounted after theforming board and provides a tun-able means of activity generationfor all product grades and basisweights.

The Vibre-Foil promotes under-wire agitation. This activity delayssheet sealing and creates opportu-nities for enhanced drainage andformation improvement. Slowdraining tables can be made moreefficient, says the company.

Constructed of 316L SST, thecustom-built VibreFoils are modu-lar with operator-friendly con-trols. They require a 110- or 220-V,single-phase power source and an80-psi air source. The companysays the VibreFoil can be mountedon a fourdrinier during a four-hour machine outage.

Case study: A study of theVibreFoil used on a 26-lb/1000 sfcorrugating-medium machineshowed the following results.

• Over all, the customer low-ered headbox consistency, modi-fied refining practices andincreased machine speed toimprove physical strength proper-ties and formation.

• Enhanced drainage resultedin increased couch solids. Thishelped to stabilize draw controland improve press performance.There was a 16% increase in thesolids with a single VibreFoil and38% with a dual unit.

• The headbox consistency waslowered by 30% which improved

fiber mobilization and wet endefficiency.

• Steam consumption fell by42% on average over six months.

• Speed increased by 8%.• Basis weights fell by 0.8%.The improved sheet properties

and uniformity along withenhanced drainage and dryingresulted in increased productivityand profitability. PIVibre-Tech LLC,www.vibretech.com

FastInfo #217

Jorg Ruppenstein,

process control

engineer, ACI, Fort

Frances Division,

E&I Services.

Vibre-Tech VibreFoil helps drainage, formation

Octopus stock approach systemsKadant AES, Queensbury, NYhas received an order for twoOctopus™ Stock ApproachSystems with ConsistencyProfiling controls from KobayashiEngineering Ltd., Japan. TheOctopus™ systems will beinstalled on Lee & Man’s new No.10 and 11 paper machines inChina. the 220 inch wide

machines will manufacture liner-board at 800 meters per minuteand will be used in place of con-ventional tapered inlets, to reducecross-machine variation and con-trol overall sheet profile. PIKadant AESwww.kadantaes.com

FastInfo #218

The Reel TurnUp Trigger (RTT) provides back-tenders with the software tools they need tobuild optimally sized reels. The RTT combinesa reel sizing calculator, on-line saleable papermonitor, left-on-spool performance trending,lost paper make-up utility and turn-up cout-down timer/alarm. The result is precisely andoptimally sized reels resulting in a minimum ofpaper left-on-spool.

Operators know precisely when a run is com-plete leading to reduced under and overruns.Maintain production run list and track numberof sets for each run: Built-at-PM, In-Process,and Off-Winder.

LSZ PaperTech Inc. Reeling and

Winding Productivity System

ADVERTISEMENT

The RTT is available as a stand-alone PCbased operator tool that is quick to install andeasy to use, resulting in very rapid left-on-spooland overrun reduction. It can also be integrat-ed with the other LSZ products to form a com-plete reel to winder quality and productivityoptimization system.www.lszpaper.com

FastInfo #166

Reel WastageMonitor

At the winder, LSZ’s Reel Wastage Monitorboth monitors production and aids the winderoperators in optimal consumption of the builtreels. The Cookie Cutter utility is a straightfor-ward program for optimal consumption oforphaned or partial reels while making uni-form final roll size. Performance trends andreports allow operators and supervisors toquickly understand and manage papermachineand winder loss time and slab losses.

RWM increases throughput by reducingpatch cycle time and reduced splice losses.www.lszpaper.com

FastInfo #168

Integrated RFIDSpool TrackingIntegratingthe RTTand theRWM usingRFID spoolt r a c k i n g ,results in ac o m p l e t edry endtime andslab losstracking and reporting system together withthe tools papermachine and winder operatorsneed to minimize time and paper losses.Results of implementation are 1%-3% produc-tivity improvement with payback time meas-ured in a handful of months.

This spool tracking enables automatic track-ing of each reel and associated production,loss, quality and other characteristics as itmoves through the process line. Allows reeland roll pedigree information to be passed todownstream information systems.www.lszpaper.com

FastInfo #167

18 ■ PAPER INDUSTRY ■ June 2006

LSZ PAPERTECH REELWORLD™ QUALITYAND PRODUCTIVITY OPTIMIZATION

Reel Turn up Trigger (RTT)• Backtender tool to optimize reel size and add

precise make-up paper at the reel• Reel density monitoring• Turn up countdown/run countdown

timer/alarms

Other LSZ PaperTech Products:Reel Wastage Monitor (RWM) Slab LossPrevention

• Optimizes consumption of reels to minimize slab losses• Precise tracking of saleable paper production & losses• Loss time analysis on reel and winder

Stop-on-Defect (SOD)• Precisely pins defects to diameters at reels and

allows winder operators to auto-slow to patchor view defect

Roll Density Monitor (RDM)• On-line roll or reel quality monitor

Roll Density Control (RDC)• Supervisory system to monitor and control

winding quality for different grades and roll diameters

System SummaryLSZ's computer systems consist of PC operator stations located at the papermachine reel,winder and any intermediate process stations such as supercalenders, coaters and rewinders.These PC operator stations are linked to a common data collection and management server.This data server receives process state, roll or reel diameter and analog signals from PLCs con-nected to tachometers, system state relays, pressure, vibration and displacement transducers.The data is stored in MS Sql Server or Oracle databases from which preexisting or customizedreports are generated. Our database is open to accept and store information collected eitherby LSZ or 3rd party systems. RFID spool tracking allows this data to be passed downstream toLSZ operator stations, roll tracking or mill wide information systems.

www.lszpaper.com

ReelWorld™ Quality and Productivity Optimization

(905) 826-5093 Email: lsz@lszpaper.com

FastInfo #111