Published N

© Valmet

RebExecutRebuildinwith over and profit

Several cascreen bascompreheoperation

The enclodelivery reincludes: mtail threadcalender,

November 14, 20

buildstive Summng a paper ma

a hundred yetability.

ase studies illuskets, throughensive rebuild

ns at many mi

osed case studequirements, machine scre

ding, doctorinreel and coate

14

s – fromary achine is a dauears of machin

ustrate the advh medium rebds that stretchlls.

dies are reviewproject milesen baskets, ev

ng, water jet taers.

Rebuilds

om s

unting task, rene rebuilds ha

vantages of Vbuilds includi

h the entire len

wed in terms ostones and resvaporator heaail cutting, he

from Small to La

mall t

egardless of thas helped cou

Valmet expertiing evaporatongth of the m

of market demsults achievedating surfaceseadbox, formi

arge

to lar

he size of the untless mills im

ise. From smaors, drying an

machine line –

mands, mill nd. The scope o, vertical imping section, p

rge s

upgrade. Valmprove effici

all rebuilds sud blow boxes Valmet has i

eeds, rebuild of the differen

pingement drypress section, d

P

cope

lmet's experieiency, produc

uch as machin, to improved

scope, speciant projects ying, blow bodryer section

age | 1

ence ctivity

ne

al

xes, ,

Published N

© Valmet

Rebuilds cproven mamachine lto much m

Let's start

Nine dA recent mrunnabilitinland reg

The Lessecompletelcellulose a

worn out screens wThis meanidle one scby the use

With convguaranteerequire twLD (Lamiboundaryresult is h

The rebuibasket, waVedahl. "A

Figure 1. Vedahl (lOuti Kukkscreen redown and

November 14, 20

come in all shaanufacturer wline. This whitmore compreh

with example

ays withomachine screety. The Lessebgion of Småla

ebo Bruk in Swly focused on and energy.

and full of puere strainer tynt they had a creen and rebe of Valmet's N

ventional wede the accept puwo or more scinar Design) wy layer as well igh screening

ilt screen, withas started in MAfter two mo

Production Manleft) and Valmetkamäki are very

ebuild. Customerd quality is up.

14

apes and sizeswith 200 yearste paper will r

hensive machin

es of smaller r

out a breen rebuild in bo Mill is loca

and, southern

weden has a loforest based p

ulp spinnings ypes, equippetotal of four s

build the otheNimax LD we

dge wires andulp quality lea

creens in parawedge wire reas reducing f

g efficiency, re

h Nimax LD wMay 2013. "Nonths we have

nager Öistein t's (then Metso'sy happy with ther complaints are

Rebuilds

s, available fos of industrialreview recent ene line rebuild

rebuilds…

eak – macSweden achieated in a densSweden.

ong history oproducts, wit

When they haa solutour supWhen conditiwith Vsatisfiea thing

One sThe heand wh

(strings). Thied with two drscreen basket

er with just onedge wires in

d drilled hole bads to an incr

allel to achieveeduces the preflow resistanceduced string

wires in the oo problems hfewer breaks

s) e e

from Small to La

r any section experience, Vexamples of mds.

chine screeves incrediblsely forested a

of paper produh a modern p

Production Mad a screeningion, "Customperior white pwe opened upion, somethin

Valmet's screened with our qug of the past."

screen baseadbox approhen opened mis was definitrilled hole bass to replace. O

ne wedge wirethe screening

baskets, the nreased pressure the desired sessure drop be through the

ging or spinni

outer basket aave occurred than ever an

arge

of the fiber, bValmet is able machine rebui

een rebuile results witharea between

uction going bproduct mix o

Manager Öistg problem on

mers were compaper and thrp the headboxng had to be dning solutionuality, and br

ket replaceach used two

mill personneltely the cause skets (an outeOn advice froe screening bag basket.

narrow slot sizre drop over tscreening effi

by optimizing e slots and theng and excell

and a blind mewith screenind production

oard, paper oto improve an

ilds ranging fr

ild h paper qualitlarge shallow

back to 1693,of graphical p

ein Vedahl (Fn PM 2 he conmplaining of createning to cx and screensdone. I am han our custome

eaks due to p

es four machine screl could see thaof the qualityer basket and

om Valmet, thasket. This wa

ze or hole sizethe screen baiciency. The pthe flow at th

e following aclent runnabili

etal plate replng since start-

n is at record l

P

or tissue mill. Any section of y

rom small sect

ty and machinw lakes in the

, and today it apers, dissolv

Figure 1) realntacted Valmeolored fibers

change supplis and saw the appy to say thers are really oor screening

eens in parallat the basketsy problems. T

inner basket)he mill decideas made possi

e needed to sket and can

patented Nimhe screen ccept channelity.

lacing the inn-up," says Öislevels with no

age | 2

As a your tions

ne

is ving

lized et for in ers.

at

g are

el, s were

The ). d to ible

max

l. The

ner stein o

Published N

© Valmet

more coloachieved aother bask

For Outi Kkind of a rin terms ocustomers

In additioother savienergy savmaintenansecond scdown. Thwearing ponly one bfour."

Now for amedium sarea of evaand dryingparticularinstallatio

SmurfiheatinThe Smurheating suevaporatio

After analdamaged surfaces bbecame a

The Smurmade frombeen contStefan Lunthinking a

"Our evapthe conce

November 14, 20

ored spots in oa record run oket, now idle,

Kukkamäki, aresult in manof days, not ms, the quality

on to the qualiings will soonvings and lessnce, because treen can be shere are also fe

parts, as there basket instead

a few examplescale upgradesaporators, blog; let's start w

rly challengingon at a Swedis

it Kappa g surfacerfit Kappa Kraurfaces had beon capacity.

lysis and discuheating surfa

became dramarace against t

rfit Kappa Kram virgin fibertinually upgrandqvist, Manat the mill:

poration plantntrator heatin

14

our superior wof nine days wfor use in an

a screening spny mills," she smonths." Veda

is better than

ity improvemn be evident (Fs the hut ewer is now

d of

s of s, in the ow boxes,

with a g sh mill.

Kraftlinees aftliner paperegun to crack

ussions with saces with Valmatic: a 350-tontime.

aftliner mill hr and is used taded and expa

nager of the Ch

t had been wong surfaces. W

Rebuilds

white grade. Fwithout a singother position

pecialist from says. "For Lesahl is in agreemn before and w

ment and the sFigure 2): "In

er switche

r mill in Swedk, resulting in

several supplimet's TUBEL nne crane coll

has an annual to manufacturanded ever sinhemical Reco

orking well, bWe finally got

Figure 2. Imp

Paper madecreasedover threeaverage o

rebuild theydays w

After baheadbox

colored spothe superio

from Small to La

From having gle break. Wen."

Valmet, the rsebo Bruk I thment. "The m

we have fewer

substantial redn addition to b

es to Valm

den was havinunplanned ou

iers, Smurfit Kheating surfalapsed, and su

capacity of 7re containerbnce. Now the

overy Plant at

but we had stato the point t

prove cleanlines

achine breaks w significantly. E

e breaks per daover five years. y have run evewithout breaks

asket change thx was cleaner aots disappearedor white paper g

arge

two to three be are now thin

results are nohink we can c

main issue," her breaks."

duction in brbetter paper m

met techn

ng problems wutages, highe

Kappa Kraftliaces. But the iuddenly the s

700,000 tonneboard. The mi

time had comSmurfit Kapp

arted having sthat it was no

ss and save mon

were Earlier ay on After n nine .

he and d from grade.

breaks per danking of a sim

o surprise, "Wcount the retue adds, "is tha

eaks, Kukkammachine runn

nology –

with its evapoer costs and so

iner chose to installation ofstandard repla

es of kraftlinerill started up ime for the evapa Kraftliner

serious probleo longer possi

ney with lamina

No spinning in

One screen inswearing parts,

Energy savshutdown

Payback tim

P

ay, we recentlymilar rebuild o

We have seen thurn on investmat for our

mäki predicts nability, there

TUBEL

ration plant. ometimes low

replace the f the new heatacement job

r. Kraftliner iin 1962 and haporation planrelates the

ems with cracible to repair t

ar design wire.

n machine scre

stead of two > less maintena

vings due to theof one screen.

me of a few days

age | 3

y of the

his ment

that are

The wer

ting

s has nt.

cks in the

een.

less nce.

e

s.

Published N

© Valmet

heating susame desievaluation

Change Once the quickly aswhen a cr

"The heattonne crancomplicatcylinder oinset). Nowork and

"In ordercollapsed company,new partsalso begansave time but we hawith the ptheir positnot normchallenginthe time lofastest, cothink thatdialogue wmain reasas well as

Good coStefan Luncontinuesfinding wplans for tother peovery goodconcentra

November 14, 20

urface, we hadgn, but made

n of our optio

of plans choice of tech

s possible. Firrane collapsed

ting surfaces ane, both to geted than we hon the crane sobody was hu

change our p

r to minimize crane we, tog

, immediatelys, dismantle thn a range of oand minimiz

ad a very openpeople at Smutive attitude wally collapse,

ng. In the endost and the inmpared to ot

t the support wwe had with osons why the pthey did in th

ooperationndqvist at Sm

s the story: "Oays forward. Athe work chanple acted very

d. Despite the ator has been

14

d to replace ite from a materons, we chose

hnology was mst, the work a

d. Valmet's Pr

are very heavet the old heatad planned fouddenly bent

urt, but we hadplans."

the time lost gether with thy started scramhe crane and rther activities

ze delays. It wn, direct and purfit Kappa Krwas a great heso this site wo

d, we managednstallation wathers with thiswe got throug

our customer people on sitehis project."

n leads to rmurfit Kappa KOur job is to m

A big challennge as much ay professionalsetbacks, we working very

Rebuilds

t instead. Onerial that was mto switch to a

made, the effoat the site wenroject Manage

vy, so for this iting surfaces or. We began t (Figure 3, d to stop the

due to the he crane mbling to findrepair it. We s intended to as a hectic tim

positive dialograftliner, and elp. Cranes doork became vd to minimize

as one of our s kind of scopgh the positivwas one of th

e could perfor

results Kraftliner

make things wge in a case lias they did helly and made ended up wit

y well since it

from Small to La

e option was tmore suitablea heating surf

ort focused onnt according ter Charlotta C

installation wout and to inshoisting the o

d

me, gue

o very e

pe. I ve he rm

work well, andke this is to mere. The coopoutstanding c

th only a smalwas started in

Figheabenmin

arge

to switch to a e for our condface from Val

n getting the nto plan, but thCederström d

we were compstall the new old heating su

d when we runmake sure thinperation with Vcontributionsll delay. I shon autumn 201

gure 3. A 350 tonating surfaces. Tnt, requiring expinimize delays.

new heating ditions. After lmet."

new heating she situation sudescribes what

pletely dependones. Things urface, but th

n into problemngs remain saValmet works. All in all, thuld also add t

13."

nne crane was uThe main hydrapert project ma

P

surface of theanalysis and

surface installuddenly chant happened:

dent on a big 3got more

he main hydra

ms, we focus oafe, even whenked well, and mhe end result wthat our

used replace theaulic cylinder (insanagement to

age | 4

e

led as nged

350-

aulic

on n the many was

e set)

Published N

© Valmet

TUBEL In kraft putakes placValmet, d

"To date, wthe worldIn the confeature a dstable mecis that thecapacity a

The instalconsumptreally hapfrom upgr

The next r

HambuThe Hambaimed to ayear after medium. maximum

In 2013, ppossibilitythe press t

An additiohad a feat

ExcellenHamburgtheir targenew solut

The mill spossibilityefficiency

The HiRuThe test ruThe guara

November 14, 20

for highestulp mills, blac

ce in large evadescribes Valm

we have comp, gaining lots

ncentrator pardesign where chanical com

e heating surfaand avoids the

llation at Smution when the

ppy about the rades of existi

rebuild involv

urger Hunburger Hungachieve betteryear. First staIt has an ann

m production

pre-dryer secty of improvinto the dryer. T

onal aim was ure that wore

nt runnabilger Hungaria bets and has alion with pass

set strict requy of a future sand a longer

un P system (Fun met all theantee for the s

14

t availabilick liquor is ev

aporators thatmet's experien

pleted more tof experiencert of the evapthe black liquponents, andace can be ease costs of hyd

urfit Kappa Keir leaking heavery good exping plants and

ves improving

ngaria boaria mill, locar results and harted up in 20ual capacity ospeed of 1,40

ion runnabiling runnabilityThis would be

to save on coe out the seali

lity and lowbecame intereso proven its

sive drilled bo

irements for tpeed increaselifetime for t

Figure 4, nexte requirementsealing lifetim

Rebuilds

ity vaporated beft are heated wnce with evapo

than 400 big ee. We have seoration train,uor is evapora this gives ousily washed cl

droblasting.

Kraftliner also ating surfacesperiences ourd in new plan

productivity a

oosts effiated in Dunaúhas been able 009, the machof approximat00 m/min.

ity became a by in the first de the next step

osts in the spang material ra

w draw ested in Valmcapabilities in

ottom rolls for

the delivery. Te up to 1,500 mhe blow box s

t page) was suts for a stable

me was also fu

from Small to La

fore it is burnwith steam. An

orator installa

evaporation averal differen, we usually reated on the our evaporatorslean during o

made it possis were exchanr customers h

nts."

and cost savin

ciency wiújváros, Hungto improve th

hine producestely 470,000 t

bottleneck forryer group, wp in improvin

are part sealinather quickly

met's HiRun bln numerous rr improved ru

They includedm/min), lowesealings.

uccessfully stae web run, fewulfilled.

arge

ed in the reconders Wernqvations:

and condensatnt technologieecommend outside of hot ts a very long lperation. Thi

ible for our cunged for our thave had with

ngs with new

ith HiRungary, 70 km sohe productivi

s 100% recycletonnes, a widt

r PM 7. The mwhich would cng production

ngs of the blowy, resulting in

low box technreference caseunnability.

d a stable weber press-to-dr

arted up at thwer breaks in t

overy boiler. Tvist from evap

te treatment pes for evaporaur TUBEL evtubes. The tublife time. Anois ensures a hi

ustomer to lotube-based tec the TUBEL t

blow boxes…

n P blow outh of Budapity and efficieed brown lineth of 7.8 m an

mill decided tconsequently n line efficien

w boxes. The high annual o

nology, whiches in recent ye

b run at 1,400ryer draw, hig

he beginning othe first group

P

The evaporatiporator sales

projects arounating black liqvaporators. Thbes are robus

other big advaigh evaporati

ower their steachnology. I'mtechnology, b

boxes pest, has alwa

ency of its PMer and corrugnd an original

o investigate reduce draw

ncy.

existing concoperating cos

h addresses boears. HiRun P

0 m/min (withgher time

of January 20p and lower d

age | 5

ion at

nd quor. hey st and antage on

am m

oth

ays M 7 gated l

the from

cept sts.

oth P is a

h the

14. draw.

Published N

© Valmet

Hungariawere one

The next r

OptiDrAt the Wowas expersupply capheating ga

The 4.7-mare three w

Figure 4. Hamburgstable webreaks an

Figure 6.

November 14, 20

, "Any action step forward

rebuild involv

ry Verticaolsan Haman riencing prodpacity. The mave them just

meter web widways to solve

The new HiRunger Hungaria proeb run, reducingnd draw.

Three ways to s

14

that reduces in our develo

ves Valmet an

al improvmill, part of Duction capaci

mill was seekinthat.

dth machine hdrying capac

P at ovided a g both

solve drying cap

Rebuilds

"It was an easus to select His known as tstandard techterms of dryesays György SProduction MHamburger H(Figure 5). "Ipleased with competent apattitude; Valmmachine line

According tocosts and imp

opment proce

d a board mil

es produDong Il Papeity limitationsng greater flex

had a speed limcity limitation

pacity limitation

from Small to La

sy decision foHiRun, since itthe industry hnology in er runnabilitySzilas,

Manager at Hungaria I am very Valmet's

pproach and met people hee competitiven

o Attila Bencsproves efficiess. Valmet m

ll solving prod

ction capr, South Kores, especially dxibility for dry

mitation due n problems (F

n problems.

arge

or t

y,"

elped and woness and prod

s, Mill Manageency is import

made this a ple

duction obstac

pacity at Wea, the testlineduring the colying and the O

to lack of dryFigure 6). One

Figu(leftManresu

rked with us ductivity."

er (Figure 5) tant. The HiR

easant and sm

cles together…

Wolsan Her and flutingld season due OptiDry Vert

ying capacity.e solution is m

ure 5. Attila Bent) and György Sznager (right) areults of the HiRun

P

to improve

at HamburgeRun P blow bo

mooth project.

…

Haman g machine PM

to irregular stical with gas

. In general, thmore drying

ncs, Mill Managezilas, Productione pleased with tn P installation.

age | 6

er oxes "

M 1 steam

here

er n the

Published N

© Valmet

cylinders finally, a stwo cylindshutdown

solutions OptiDry Vcontrol.

Installatioenhances while the cases Optand there need to finconstructi

OptiDry VproductioOptiDry Vproduct q

Great reThe targetout proceday shutd1,050 m/m

Finally, wLWC mill

Stora EPM 5 in Sof high-qu

Figure 7.

November 14, 20

with a 3-levelshort drying sder drying capn times; they a

offering diffeVertical for dr

on of an OptiDdrying, but cdry content iiDry Verticalis no extra sp

nd space for eion work and

Vertical offerson capacity inVertical technquality and it s

esults at tht of the rebuilss conditions

down, the rebumin to 1,200 m

we'll look at larl…

Enso VeitStora Enso's Vuality LWC p

OptiDry imping

14

l drying sectiosection with Vpacity solutioalso require m

erent benefits rying capacity

Dry Vertical ian also allow s raised, thus is the only po

pace in the maextra drying c

d a shorter shu

s increased drcrease with o

nology it is posuits different

he Wolsan ld was to incrduring the co

uilt machine wm/min with 1

rger scope rebu

tsiluoto imVeitsiluoto mipaper per day.

gement drying p

Rebuilds

on; another isValmet's Options are expensmore steam ca

for papermaky increase, esp

impingementthe steam preimproving th

ossible way ofachine room.cylinders and utdown time.

rying capacityne dryer is ar

ossible to dry t drying layou

mill rease the dryinold season, anwas started up80 g/m2 end p

uilds, starting

mproves ll in Kemi, no In 2011, the

principle

from Small to La

s more dryingDry Vertical sive and requ

apacity, which

kers. OptiDrypecially in reb

t dryer at the bessures of thehe drying effef increasing p The dryer wito relocate th

y without addround 15%, giall paper and uts.

ng capacity bynd to get morp in May 2012product.

g with a comp

runnabilorthern Finlancompany dec

arge

g cylinders wiair dryers wit

uire a lot of coh was not avai

Vaim(Frepcydrhigcreretthth

y Twin for drybuilds, and O

beginning of e cylinders to ect of the currproduction if ill be located

he dry end equ

ding machine iving the pote board grades

y 14%, to impre flexibility fo2. The machi

rehensive pro

ity and efnd, is able to cided to inves

ith a longer drth several hea

onstruction woilable at the W

almet's revolumpingement dFigure 7) has b

place and impylinder dryingrying, hot air igh speed agaieate high dryturning air is e evaporated ree impingemying capacity ptiDry Horiz

the dryer sectbe increased

rent equipmenthe machine in the basemeuipment. Thi

length. The aential for a sps without cha

prove the runor drying. Aftine speed was

oduction effici

fficiency produce mor

st in improvin

P

rying section;ating options. ork and long

Wolsan mill.

utionary Optidrying technobeen developprove traditio

g. In impingemis impinged ainst the web t

ying capacity. used to carrywater. Valme

ment drying and bulk sav

zontal for curl

tion not only without sticknt as well. In mis drying-liment so there isis means less

average eed increase.

anging the end

nnability, to evter the short ss increased fro

ency upgrade

re than 700 tong the line's

age | 7

; or, The

iDry ology

ed to onal ment at to The

y out et has

vings, l

yking many ited s no

With d

ven seven-om

at an

onnes

Published N

© Valmet

runnabilitresult, the

Stora Enspapers froAt the samline. It has

At the endproductiobut prelim

"We wantbreaks anthe reel. Amodel wasays Mark

From the was obvioimprovembe accomptricks, butimprovemthroughou(Figure 8was choseupgrades.

UpgradmachineFrom the operators significanduring thethreadingwhereby twere addeThe upgra

"In this prproject frothe first uValmet ofMatilaine

November 14, 20

ty and produce number of p

o's Veitsiluotoom mechanicame time, Veitss the capacity

d of 2011, Veion efficiency. minary survey

ted to improvd shortening

At the same timas sought for tkku Åman, Pr

start of the prous that the ments sought cplished with jt technologica

ments were requt the produc). In April 20

en to carry ou

es throughe line point of viewof PM 5, the

nt change impe project conc

g of the paper two tail threaded to the presades made wo

roject, the scoom start to finpgraded comffers for the pn, Global Tec

14

ction efficiencproduction br

o mill is an inal pulp and sasiluoto's PM 5

y to produce m

itsiluoto madThe previous

ys into new de

ve the paper mthe break timme, we had othe LWC paperoduction Ma

roject it

could not just a few al quired ction line 12, Valmet

ut the

hout the

w of the most lemented cerned tail web, ding units s section. ork easier at th

ope of the impnish; from the

mponent, the Paper grade. U

chnology Man

Rebuilds

cy. With Valmreaks and the

ntegrated prodawn products5 has the honmore than 700

de the decision major chang

evelopment o

machine's efficme. One object

ur own efficieer machine to

anager of the p

he press secti

plementation e press sectionPressForce. ThUsually, the upnager at Valm

Figure 8.

TwinRunRoll geomthe paper cylinders w

HiRun 20A runnabilfast paper

PressFoTail threadin press se

DoubleJWater jet ctail on cylidraw or ag

from Small to La

met's help, PMamount of br

duction facilits. It is the fournor of being th0 tonnes of hi

n to invest in ges to the prodptions for PM

ciency over timtive was to alsency developmo enable operaprinting pape

on.

was exception to the reel. Ahe line now upgrades conce

met, who parti

Key technologie

nmetry used in dou

web in the openwith the help of T

000lity box designedr machines.

rceding unit picks anection open draw

etcutting device, cnder surface, atgainst the dryer

arge

M 5 was upgraroke were sign

ty manufacturth largest paphe world's norigh quality No

improving PMduction line w

M 5 had been

me by decreaso decrease thment project ating the proder mill.

nal in that it wAs soon as th

uses nearly eveern smaller suicipated in pla

es of the Veitsilu

uble-fabric groun draw between TwinRun runnab

d for UAs

TLpc

nd carries tail ws.

cuts t open fabric.

aded to increanificantly dec

uring office paper and boardrthernmost povaPress LW

M 5's runnabwere made in made since 2

asing the numhe amount of in progress: aduction with

was a complehe tail threadinery tail threadubsections," sanning the pr

uoto PM5 projec

ps to support top and bottom

bility boxes.

UnoRollA bottom cylindesingle-fabric area

VacRollA groovedcylinder in

Tail threadingLow-friction Blowplates between dcalender. FoilFor

P

ase efficiencycreased.

apers, coated d mill in Euro

paper productC every day.

ility and the mid-1990000.

mber of producf broke createda new operatifewer person

ete tail threading starts, we rding unit thatays Pekka roject.

ct

m

DoublDoctor surface

er in the dryer sea with a grooved

d and perforatedn the single-fabr

in calender-rwForce tail threadryer section anrce tail threading

age | 8

y. As a

ope. tion

0s,

ction d at ng

nnel,"

ing reach t

eDoctorkeeps roll

e clean.

ection d surface.

d bottom ric area.

reel areaading d g units.

Published N

© Valmet

The dryeralso upgrarunnabilitupgraded

"Before thtypical prosomewherdrying stasituation wrunnabilitalso madechanges, w

Some of thpotential cupgraded factor conbeen work

ReducinSeveral dimeasure w

"Reel areatechnologÅman.

Throughoatypical soin the reelbreak. Whthere is le

Åman conthree kilomthat there

The amouenergy is w

The tail thwhich wermonitored

November 14, 20

r section's runaded during tty boxes locatto use the lat

he upgrade, woblem where re interruptedage. We soughwith new Vacty boxes by dee to eliminate we also reache

he technologicauses of breaduring the m

ntributing to bking superbly

ng the amoifferent technowas the most

a tail threadingy chosen star

out, well-testeolution used wl-calender arehen threadingss broke."

nfirms the obmeters of bro is nearly 2.5

unt of broke iwasted as it is

hreading warrre reached. Ad. Performan

14

nnability packthe project. Thted at its starttest technolog

we suffered froa minor fault

d the process ht to improvecRolls and ecreasing papan edge flutt

ed our targets

ies were choseaks were cons

modification wbreaks causedy.

ount of broological imprsignificant?

g was the toprted to work f

ed technologywith PM 5 waea: "This solutg takes place i

servation: "Eaoke per parentkilometers le

s also decreass not used for

ranty tests incAccording to Å

ce and efficie

Rebuilds

kage was he were

gy.

om a t at the

e the

per web breaker problem ins," Markku Åm

en only after sidered and itwork. It was ind by precipitat

oke rovements we

pic that we hadfrom the first

y was employeas the middle tion was empin the middle

arlier, when tht roll during ass broke per b

sed by the factr producing th

cluded preciseÅman, the valency have rem

from Small to La

ks. The solution the double-fman says.

the sales projt was decided ncluded in thetion. Accordi

ere implement

d to consider tail threading

ed in the projthreading anloyed to decr, roll bottom

hreading tooka break. Now break."

t that there arhe extra broke

ely defined telues defined fo

mained within

Figure 9. Vei

arge

on proved sucfabric area (T

ect had alreadthat the 3rd pe package becing to Åman,

ted during th

most carefullg and has bee

ect. Pekka Mnd spreading trease the amouformation is

k place at the the figure is 5

re fewer breake.

est values for tfor the projectn the target va

itsiluoto PM5 in

ccessful. CertaTwinRun), and

dy been startepress doctorincause poor dothe new doub

he project, but

ly in advancen reliable eve

atilainen thinto both directunt of broke fine after just

edge, there w500–600 mete

ks. And with

tail threadingt are constant

alues.

n Kemi, Finland

P

ain changes wd with these

ed. At Veitsilung should be octoring is onble doctor has

t which techn

. However, ther since," says

nks that the mtions implemecreated durint a few rounds

was approximers. This mea

fewer breaks,

g run-throughtly being

age | 9

were

uoto,

ne s

nical

he

most ented

ng a s, and

mately ans

, less

hs,

Published N

© Valmet

From paStora Ensmajor instshutdownrequired cAccording

"The impexperiencto become

The projeoperating

"I can honincluded tcourse, thvariety to the job of process. Timproving

"Thanks tapproximrunnabilitthe way topropositio

The final c

ProjectSappi is omatter horaft of oth

At this cruof cut, cutbolder app

"The existWiersum.more than

"Our existcontinuesusing lots

November 14, 20

aper to papo and Valmettallation work

n of a week. Prcareful plannig to Åman, th

plementation fced team bothe obvious tha

ect's business b it produces m

nestly say thatthe impact on

his requires extheir work," Å

f operating theThe focus of fug the quality o

o the upgrademately four cen

ty boxes. If weo the customeon on this has

case study is f

t Leopardne of the wor

ow good thoseher electronic

ucial crossroat and cut somproach was ta

ting PM 2 at A. "And a graphn paying their

ting specialty s Wiersum, "O

of plastic to u

14

per in eight signed an agk was carried reparation woing and doinghe work was c

from paper toh from us and t we had mad

benefits and pmarketable LW

t we have reacn personnel. Wxtensive experÅman says. Ae rereeler, as turther develoof the finished

es implementntimeters wide could cut aner. This woulds already been

for a specialty

d at Sapprld's largest pre products aremedia device

ads, Sappi coume more. How

aken; to signif

Alfeld was loshic paper macr way in speci

papers' custoOne that couldusing lots of p

Rebuilds

t days greement on t

out during work had alreadg as much as pcompleted wit

o paper durinfrom Valmet

de the right ch

payback perioWC as efficien

ched the mainWe can now ortise from the

A third employthe PM 5 coatpment is currd product.

ted at PM 5 inder than beforn equally wided require somn made," says

paper machin

pi Alfeldroducers of hie, the introdues have put a l

uld easily havewever in the ca

ficantly expan

sing us a lot ochine sitting iialties made n

omers were ted cope with lapaper instead

from Small to La

the Veitsiluotweek 42 of thedy been startepossible in adthin the sched

ng the shutdowt participated hoice about th

od are based ontly as possib

n objectives seoperate the mem, but at the yee is locatedter is not direrently on the

n 2012, we canre. This is large web at the c

me additional iMarkku Åma

ne comprehen

igh quality, coction of the iPlarge dent in

e introduced ase of Sappi Fnd into the lu

f money", sayin the middle

no sense at all.

lling us that targer orders, a– a growing t

arge

to PM 5 upgrae same year, wed by then. Th

dvance, beforedule.

wn took eightd in the installhe technology

on the improvble.

et for the projmachine with j

same time, itd at the dry enectly connectefinal part of t

n now get a wgely thanks tocutter, we couinvestments oan.

nsive rebuild…

oated graphicPad, the Samsgraphic pape

the unimaginFine Paper Euucrative marke

ys Sappi Fine e of four other."

they liked theand one that trend in Euro

ade work in Awith a schedulhe success of e the actual sh

t days. A highlations. At thay."

ved efficiency

ject. The efficust two profet brings morend of the proded to the prevthe productio

web out of theo the VacRollsuld bring the mon the coating

…

c papers. Unfosung Galaxy, r demand.

native managerope's Alfeld et for specialt

Paper Europer paper mach

e idea of a 'bigcould ease th

ope."

Pag

April 2012. Thled maintenanthe project

hutdown.

hly competentat stage, it star

y. When the li

ciency objectiessionals. Of e interest and duction line wvious parts of on process, in

e machine thas and the newmaterial beneg machine. A

ortunately, nothe Kindle, a

ement philosomill, a much

ty papers.

e CEO, Berry ines which w

g' machine," he transition fr

ge | 10

he nce

t, rted

ine is

ives

with the

at is w efit all

o and a

ophy

were

from

Published N

© Valmet

Let ProjThe histormill itself.Sappi's cu

One of this directorunusual siwell in a gdeclining a year, anddue to lac

"We thouaround," cconvincedwhich is mwith the b

The concemm that c1,200 m/ma specialtygrade cha

It was a clspecialties

In May 20Brussels ththat will in

Karrer deplan for P

Another 1Leopard c

Figure 11

November 14, 20

ject Leopary of the idea . The name ca

ustomer calen

ose people inr at the Alfeldituation at Al

growing markmarket. The d the graphick of orders. W

ght about havcontinues Kard we could demuch faster thbold plan of g

ept for the necould handle min. This wouy machine to nges.

lear plan froms.

011, the Alfeldhe ambitious ncrease our sp

scribes the mPM 2 was put

14 months latcommenced, a

1. Sappi Alfred P

14

rd commenfor what was

ame from an adars – a perfe

strumental ind mill, Dr. Steplfeld, four speket and one grfour specialty paper machi

We had to do

ving a minor rrer, "But spe

eliver the qualhan a 'normaloing the who

w PM 2 was fintricate grad

uld mean that20 tonnes per

m the start tha

d team includplan to rebui

pecialties by 1

management teforward, whi

ter, in July 201and Valmet w

PM2 includes a n

Rebuilds

nce! s to become kaction photo ect illustration

n the idea of thphan Karrer (

ecialty machinraphic machiny machines weine was subjecsomething.

rebuild, and tcialties is ourlity, particularl' specialty male way and do

for a world-cldes of basis wet production wr hour. The m

at PM 2 was g

ding Karrer prild PM 2 (Fig135,000 tonne

eam at the prech was then b

12, and after awas appointed

new headbox wi

from Small to La

nown at Sappof a Leopard

n of the plan f

he transforma(Figure 10). "nes that were ne that was stere running 2ct to commer

tackling specir business, andrly at the speeachine. Then oing a comple

lass, prototypeight range 40would leap fr

machine would

going to becom

resented to Saure 11) into wes/yr."

esentation as broken by CE

a lot of serioud as the main

ith forming, pre

arge

pi as Project Lleaping from

for PM 2.

ation of PM 2"We had an doing really

truggling in a24/7, 365 daysrcial standstill

ialties that wad we were noted of PM 2, we came up ete rebuild."

e specialty m0-180 g/m² anom the five od also have to

me a star pape

appi's Europewhat he descr

going compleEO Wiersum,

us studies, dissupplier for t

ess, dryer, calend

Leopard startem one rock to a

2

a s ls

ay t

achine with and run at a pr

or six tonnes po cope with nu

er machine in

ean managemribed as "som

etely silent aftuttering "Wo

scussions and the project.

FigurKarreproje

der, reel and coa

Pag

ed at the Alfelanother on on

a width of 5,15roduction speper hour normumerous, com

n the world of

ment team in ething fantast

fter the ambitiow!"

site visits, Pr

re 10. Dr. Stefaner has lived withect from its ince

ating sections re

ge | 11

ld ne of

50 eed of m for mplex

f

tic

ious

roject

n h the

eption.

ebuilt.

Published N

© Valmet

Sappi AValmet's sheadbox wingredienmachine amultinip csupplied a

Mauri Lau"From theone – a tointerestinbeing proobtain the

"We trialecalenderinthat the Sathey alway

A carnivWim DevLeopard'ssuppliers,as the facia gut feelichoice of

With the oteam, the steering cSappi andwell as theof the mas

The journnot so muthe mill wauthority villages anover 120 t

When theonly one obiggest en

November 14, 20

Alfeld: a descope of suppwith dilution ts in the rebualso has a comcalender rebualso included

urikainen, Vae beginning wotally online cg challenges aduced on a we base paper s

ed many of thng demands wappi Alfeld mys came at us

val atmospvens, the comp leader from t and in the enilities for the cng among thesupplier."

order in placemill team, anommittee ma

d Valmet - to ee guarantees ossive Yankee

ney itself fromuch of a problwas full of chal

approvals to nd over bridgtrees had to h

e Yankee finalof the most ex

ngineering pro

14

manding cply was a comp

circulation, fouild is a brandmpletely new cuild with exist

a DNA qualit

almet's senior when the conc

oncept with fare the wide b

wide machine surface quality

he grades at ouwould work a

mill was a demwith their ide

phere pany's managthe Sappi sidend it came oucasting of thee team at Sapp

e, it was then nd the supplieade up of the sensure the deof quality. Bucylinder to ar

m Sweden to Glem, but the rllenges, says Dallow the Yanes to the mill.

have branches

lly arrived in xciting projecoject going on

Rebuilds

customer plex and all-e

forming, pressd new solid cacoating sectioting Nipco rolty control sys

paper technocept was first pfinished prodbasis weight rat speed. They.

ur pilot plantscross the grad

manding custoeas in a coope

ger of central te, he says: "Wt that Valmet

e Yankee cylinpi that Valme

left to Deveners – which wesenior manag

eadline for timut first, there wrrange.

Germany by boad trip fromDevens: "It tonkee to pass th. Street lightinsawn off – 10

Alfeld, it was cts the town on in the whole

from Small to La

encompassings and dryer sesting 6.4 m di

on with air drlls, a reel rebu

stem and mac

ology managepresented, it wucts coming oange and the

e Yankee cylin

s in Finland mdes needed," c

omer for this perative fashio

technology anWe went throug

t had the expender. There wet was the righ

s and the proere all oversee

gement of botming was met,was transporta

boat and bargem the river por

ok over 100 lhrough townng had to be d0 trees had to

to somethingof Alfeld had se of Germany

arge

g one; the newections rebuiliameter Yank

ryers plus twouild and brokchine control

er for paper mwas clear thisoff the end ofdiffering spec

nder of course

making sure tcontinues Lauproject, but thn."

nd engineeringh the whole erience and kn

was also ht

oject en by a th , as ation

e was rt to ocal s and dismantled, h

o come down

g of a carnivaseen for somey which was b

w PM 2 has a t. One of the

kee cylinder wo ValCoat coake collection. T

PCS7.

mills says of ths was going tof the machinecialty grades, e was an abso

that the coatinurikainen. "Thhey knew wha

ng (Figure 12process with

now-how in s

high voltage cacompletely.

al atmospheree time, but it wbeing hit by th

Figure 12. Wimtrust in Valme

Pag

completely nessential

with hood. Thating stations,The automati

he PM 2 projeo be an unusue. Added,

at the same tolute must to

ngs and here is no douat they wante

2) was Projectthe main

specialties, as

ables lifted an

e as this was nwas also the he economic

m Devens has gret's performance

ge | 12

ew

he a ion

ect: ual

time

ubt d and

t

well

nd

not

reat e.

Published N

© Valmet

On the 17reels. "It wto go out t

Since thenquality grwhat is neoptimizatahead of icoater, wiexpectatio

Devens cofrom Valm

"BiggesPerhaps thStephan Kproject rebeen tirinworking o

SummRegardlesout your pwoodyardValmet lo

Figure 13diameterdeliver.

November 14, 20

7th October, awas part of theto our special

n, by the first ades required

ext? Devens saion stage, and

it; we are expeithout coater, on we have."

oncludes: "Wemet whenever

st experienhe most impo

Karrer who orally has been

ng for everyboon what is goi

ary ss of the rebuiproject from sd all the way tooks forward t

3. The impressivr Yankee was a c

14

and again abse agreement wlty customers

half of 2014 md for its demaays: "Well, thed we are ironiecting it to doone side, two

e are really har we have nee

nce of my liortant person riginally camethe biggest ex

ody, but it making to be such

ild size, Valmstart to finisho finished rolto accomplish

e 6.4 meter challenge to

Rebuilds

turndthe wthe stbarbewoodvisito

TheOn ththe seavailarebui

Valmand owas sDeve

olutely accordwith Valmet ts," adds Deven

more progresnding, discere work doesning out the pro all grades froo sides, all tho

appy all in all eded it during

ife" to finally ask

e up with the xperience of mkes me so pro

h a remarkabl

et has the exp. Our capabillls leaving thehing demandi

from Small to La

down. Devenswhole county treets, and hoecues and pardyard, and onors came to se

race is onhe 30th of Auerious race toable for the inild.

met gave the aon October 12stock on the wens.

ding to plan, that we had tons.

s had been mning custome

n't end for us uroblems that gom 50 to 180 ose different p

with how it hg the installati

k about the suconcept: "Ap

my life. The laoud that the we machine wh

pertise and prities extend fr

e mill. Special ing projects w

arge

s said, "Whenhad turned o

ouses alongsidrties. We had n the first weeee the huge Y

ugust 2013 theo the finish benstallation of

assurance that2th 2013, exawire. "We cou

Alfeld produco have two jum

made and PM 2ers to its own until the end go with that. Tg/m² with ca

parameters, an

has gone and ion and start-

uccess of the Part from the bast few monthwhole PM 2 tehen it is fully

roven track rerom the point delivery requ

with our mill p

n the Yankee ut to watch, p

de the route wa small viewi

ekend somethankee."

e 'old' PM 2 wegan, there wethe Yankee (F

t the project wactly accordinuldn't quite be

ced the first tmbo reels full

2 could produquality benchof July. We arThis machine

alender, withond all at high

we have had up phase."

PM 2 project ibirth of my twhs optimizingeam are still sup to speed."

ecord to safelyt that logs comuirements arepartners.

Pag

arrived, it wapeople were owere hosting ing area in th

hing like 1,500

was shut downere only 39 daFigure 13) an

would take 39g to plan, theelieve it," says

two saleable jul of saleable p

uce all of the hmark Q1. Sore now in thee has quite a tout calender, w

speed. It is a

splendid supp

is mill directowo children, tg the start-up o delighted to

y and reliablyme into the e not a proble

ge | 13

as as if out on

e 0

n and ays nd the

9 days, re

s

umbo paper

top o e task with high

port

or, Dr. this have

o be

y carry

m, as

Published N

© Valmet

This white papers.

Valmet proand power fabrics. Ouservices.

We are com

November 14, 20

paper combine

ovides competitr professionals ur offering and e

mmitted to mov

14

es technical inf

tive technologiespecialize in prexperience cov

ving our custom

Rebuilds

formation obtai

es and servicerocesses, macver the entire p

mers' performa

from Small to La

ined from Valm

s to the pulp, echinery, equipmprocess life cyc

nce forward.

arge

met personnel a

energy and papment, services, cle including ne

and published V

per industries. paper machine

ew production li

Pag

Valmet articles

Valmet's pulp, e clothing and lines, rebuilds a

ge | 14

s and

paper filter and