Content on this page requires a newer version of Adobe Flash Player.

Paper Making & distribution Magazine Volume 17 Issue 15

PMD magazine

___Magazine Data___

Increase refining performance and lower power costs DD®6000Refiner Upgrade your medium consistency pump to reduce power consumption and maintenance costs Handle up to 2% feed consistency with up to 50% less energy CellecoTwister® Cleaner Luthi™ Rotor Realize power savings and increased rotor and screen plate life by installing this state-of-the-art rotor. These are just a few of GL&V’s cost saving solutions to your existing equipment. GL&V also provides process equipment and upgrades for fiberlines, stock preparation, recycle systems and paper machines. Contact your local GL&V representative to review our complete line of products and upgrades. GL&V Sweden AB • find it all @ www.glv.com © Copyright 2009 GLV. All rights reserved. A s I wondered what to include in this issue’s comment, my email sprang into life with new messages and it was pleasing to see good news for a change. First was from ABB and how they will be building a new factory to manufacture its Quality Control Systems (QCS) for Pulp and Paper in Shanghai, China. The second item was from UPM Shotton and the ceremony in which it was presented with the Queen’s Award for Enterprise: Sustainable Development by Her Majesty’s representative Lord Lieutenant Trefor Jones CBE at the newsprint mill on Deeside Industrial Estate. This positive news was also echoed during the Honeywell users group meeting held in Helsinki (29-30 September and 1 October) that I was pleased to attend. A number of new developments were displayed for pulp & paper professionals. The company’s efforts to provide new and novel solutions were available for all to see. Look out for the 2010 editorial schedule, which will soon be posted on PMD web site. Suppliers of services, equipment and processes get in touch if you have any news of interest to readers in the global pulp & paper industry. More immediate is the November-December issue which will include our logistics update, machine clothing, and a preview for Paperex India, what’s new from pump and valve suppliers plus developments in bearings, gearboxes and drives. If readers have any areas or subjects worthy of investigation please email me, Vince Maynard, at pmdmagazine@btinternet.com with your ideas. Finally, while good news is always welcome, we can’t forget the devastation that has hit Indonesia. We offer our thoughts and prayers to our readers in the region. Vince Maynard Publication manager & editorial controller 2 - 7 Industry news 8 - 10 Projects & Contracts 12 - 13 Dow Corning: Surface specialists 14 - 15 Product news 16 - 18 Cham Group: Innovation out of tradition 20 - 21 Brammer: Safety in numbers 22 - 24 Heimbach: How forming fabrics can reduce power consumption 25 - 27 GL&V: New twists to hydrocyclones 28 - 29 Voith Paper: Space technology for dewatering 30 People 31 - 32 From the shop floor 32 Trading Post Leading power and automation technology group ABB is planning to build a new factory to manufacture its Quality Control Systems (QCS) for Pulp and Paper in Shanghai, China. The new facility will result in the transfer of about 60 jobs from an existing plant in Dundalk, Ireland. The research and development (R&D), product support and marketing functions will remain in Dundalk. The QCS business is part of ABB’s Process MOVING TO CHINA: ABB’S QCS Automation Division, Pulp and Paper PRODUCTION OF SENSORS Business Unit. Roger Bailey, global manager of ABB’s with the market demand. Pulp and Paper business, said the “Most new paper machines are being decision to locate the new factory in built in Asia, and to better support this Shanghai was based on ABB’s demand, we needed to invest in the continuing strategy to align its footprint region,” he said. Volume 17 Published under licence by: Hartswood Media ISSN 1479-3989 Vol. 17, Issue No. 15 September/October 2009 Accounts -June Bray Editorial advisor -John Nutting Consultant editor -David Young Production -anton.print1@btconnect.com Production editor -Justin Whitsed Publication Manager & Editorial Controller Vince Maynard +44 (0) 1732 505724 Mobile +44 (0) 7747 002286 Fax +44 (0) 1732 860052 E-mail: pmdmagazine@btinternet.com or pmdeditorial@btinternet.com Circulation – circulation@pmdmagazine.com Nordic representative Einar Johansson E-mail einar.johansson@telia.com Publisher -Paul Barrett paulbarrett@pmdmagazine.com Paper Making & Distribution is published under licence by: Hartswood Media Hallmark House 25 Downham Road Ramsden Heath Essex CM11 1PU England T- + 44 (0) 1268 711560 F- + 44 (0) 1268 711567 Repro by: Anton Print Solutions Email: antonprint1.btconnect.com www.antonprintsolutions.co.uk Printed by: Holbrooks Printers Ltd, Norway Road, Hilsea, Portsmouth, Hampshire, PO3 5HX. Tel: 02392 661485 Digital Conversion by: Print to Digital PAPER MAKING & DISTRIBUTION Industry News Quality control systems production to move to China Cascades completes Atlantic’s tissue division acquisition Leading Canadian packaging and tissue products manufacturer Cascades has completed the C$60 million acquisi­tion of Atlantic Packaging Products’ tissue division. It will enable Cascades to increase its annual capacity by 55,000 short tons of recycled paper and its converting capac­ity by about 70,000 short tons, adding close to C$100 million in sales per year. Suzanne Blanchet, chief executive of Cascades Tissue Group, said: “Cascades Tissue Group has dedicated considerable resources to the development of the Cascades Enviro100 per cent recycled brand, to the point where it is now considered to be the number one green brand in the country, according to AC Nielsen. “This transaction will enable us to fur­ther the development of the Cascades Enviro100% recycled brand particularly in central and western Canada by bring­ing us closer to our customers who are located west of Quebec.” Alain Lemaire, chief executive of Atlantic Packaging, added: "This acquisi­tion allows us to further consolidate our position as a leader in the development of environmentally-responsible products. “Atlantic Packaging Products has been using recycled fibres to manufacture its products for many years. Building on this experience, Cascades will ensure that its environmentally sound principles are applied to existing processes, namely, with regards to green chemistry and mini­mal consumption of water and energy.” PAPER MAKING & DISTRIBUTION Industry News Metso’s Fiber business line to cut 400 jobs M etso wants to cut about 400 jobs at its Fiber business line (FBL) operations, which supplies chemical and mechanical pulp industry customers with machinery and equipment. It wants to “improve competitiveness in a changing business environment” and started negotiations with unions at the end of September. The jobs are about a third of the 1,200 at FBL in Sweden and Finland. It says the reductions are part of the process to streamline FBL’s operations and cost structure, and to improve its competitiveness in a changing business environment. Additionally, they will improve operational flexibility and further strengthen FBL’s local operations, close to customers in growing markets. FBL has initiated major changes in its organization to meet geographic shifts in the pulp and paper industry, and to declining demand for capital equipment and for project sales. As part of this process, FBL’s five business units will be consolidated into two streamlined units (Fiber Processing Unit and Wood and Pulp Handling Unit) and Services. As a result of the restructuring, FBL’s annual costs are estimated to decrease by more than 20 million euros. The cost savings will first be made fully in 2011. One-off restructuring costs are estimated to be 15 million euros, most of which will be in the final quarter of 2009. Job cuts in Sweden are expected to be 168 at Sundsvall, 219 at Karlstad and 130 at Hagfors. In Finland the cuts are expected to be 95 at Pori and 17 at Valkeakoski and Jämsänkoski. • Improved performance is being brought to all pulp mill processes by a control system recently developed by Metso. Called Metso Advanced Process Control (mAPC) and developed in collaboration with pulp mill engineering and operations personnel, it uses predictive controls to eliminate shift-to-shift variations from the wood yard to pulp dryer. Fabric plant starts up in China Dow raises latex-based products prices Production started at Heimbach Fabrics (Suzhou) Co Ltd in China in June. The plant makes the forming and dryer fabric designs for distribution to Heimbach’s customer base in China, and for export elsewhere in the Asian market. Peter Michels, chief operating officer of Heimbach, attended the opening ceremony from the Düren headquarters in Germany. Guests included the German Consul-General to Shanghai, and the Chairman of Suzhou Industrial Park, as well as representatives from the German, Swiss and Chinese Textile Federations. Dow Emulsion Polymers increased the prices on all styrene butadiene latex based products sold by its Emulsion Polymers business into the paper & paperboard, carpet and performance latex indus­tries by 200 euro/MT (dry) in Europe, India, Middle East and Africa in September. The company, a business unit of The Dow Chemical Company said the increase was “critical to help offset the last two months’ explosive rise in costs of raw material needed to manufacture our products”. VCP’s Penido leads RISI’s global industry top ten The RISI group, which produces PPI magazine, published its Power List for 2009 with VCP’s chief executive Jose Luciano Penido at the top for the second consecutive year. The top ten is: 1. Jose Luciano Penido, Votorantim Celulose e Papel; 2. Chen Hongguo, Shandong Chenming Paper; 3. John V Faraci, International Paper ; 4. A J Devanesan, Asia Pacific Resources International Holdings Limited; 5. José Honório, Portucel Soporcel Group ; 6. Dr Wolfgang Palm, Palm Paper; 7. R R Vederah, BILT ; 8. Teguh Ganda Wijaya, APP; 9. Duncan Pollard, World Wildlife Fund; 10. Cheung Yan, Nine Dragons Paper. PAPER MAKING & DISTRIBUTION Industry News Sustainable development award for UPM Shotton T he UK’s largest producer of newsprint from recycled newspapers and maga­zines, UPM Shotton was officially awarded a Queen’s Award for Enterprise: Sustainable Development by Her Majesty’s representative Lord Lieutenant Trefor Jones CBE at the beginning of October. In a short ceremony at the newsprint mill on Deeside Industrial Estate, president of UPM’s Paper Business Group, Jyrki Ovaska and general man­ager of UPM Shotton, David Ingham received a rose bowl to mark the achievements the newsprint mill has made towards sustainability. The paper mill, which gener­ates its own electricity and steam from paper making residues, was praised for having achieved the highest standards of sustainability throughout its business operations. UPM Shotton was granted the award as recognition for outstanding performance in environmental sustainability and its positive impact on the local community. “I would like to express my thanks to our customers, our suppliers, the local authority and community groups, as well as our regional & national gov­ernment representatives for their support and guidance,” said Ingham. “These long-term con­structive relationships have underpinned this achievement. “Finally, I would like to offer my warm congratulations to the UPM Shotton team. The Queen’s award for Sustainable Development is recognition of the determination, hard work, loyalty and skill they have shown and will continuously improve on into the future.” They were joined by cus­tomers, employees and local stakeholders for the event during which a celebration cake was cut by the Lord Lieutenant. Huyck.Wangner outlines its strategy I n the face of increasing market pressure in the global economic downturn which has created worldwide overcapacity, paper clothing specialist Huyck.Wangner outlined its future business strategy at Zellcheming. Its response is to focus on its traditional core competencies: technology leadership, first- class quality and one-of-a-kind service with the launching of a ‘Made in Europe’ initiative, which will see strategic investments focus on expanding the company’s product portfolio and sales activities in Europe. Demand from consumers and industrial paper users was already weakening in 2008 but production figures for the first quarter of 2009 showed sector declines of between 17 and 21 percent. With the objectives of top machine efficiency together with low labour and energy cost targets, Huyck.Wangner’s Made in Europe strategy uses a three-element strategy including technology, quality and service, for both forming and dryer fabrics, as well as press felts and industrial textiles. Xerium Technologies, Huyck.Wangner’s US-based parent company, views the cancellation of projects in Asia, including a planned production facility in Vietnam, and the shifting of the investment focus onto Europe, as the way to address the current crisis. It is also pressing ahead with a new product offensive by delivering clothing based on ‘cost per ton’. Investment spending this year is being directed toward four projects. By the end of 2009, a new loom will have been installed and started up at the forming fabric production plant in Reutlingen, Germany. More than 15 metres wide, it merges all of the latest weaving technologies and will enable Huyck.Wangner to further improve the first-class product quality of new generations of forming fabric. Three investment projects are being planned for Gloggnitz, the Austrian production location for press felts, dryer fabrics and industrial textiles. Huyck.Wangner built another high-performance calendar, which will add a further 180 tons per year to the location’s clothing production capability. An ultramodern loom will also be installed for press felt making. Equipped with multi-shaft weaving technology, it will be used primarily to manufacture the new exxact press felt designs. The investment budget also includes funding for new press-felt technology that is based on research into first principles and a design concept, described as unique, will be unveiled at the end of the year. • Xerium Technologies is based in the US in Youngsville, North Carolina, and incorporates the leading paper industry brands Huyck.Wangner, Weavexx, Stowe Woodward and Mount Hope, and last year had sales of US$638 million, of which about 64 per cent was attributable to paper machine clothing and the remainder to rolls. PAPER MAKING & DISTRIBUTION Industry News Calls for more consolidation in the global paper industry T he paper industry needs more consolidation, Nordic producers UPM-Kymmene, M-real and Norske Skog told the Reuters Paper and Packaging Summit in Helsinki held at the end of August. The global paper industry has struggled for nearly a decade to climb out of a slump caused by overcapacity, soft demand, low prices and weak earnings, heightening the need to consolidate. But deals have been scarce throughout that period, and an analyst said financing, valuation and competition issues would likely continue to constrain players’ options. UPM-Kymmene’s chief executive Jussi Pesonen said his company aims to be an active player in the consolidation of an industry struggling to slash costs and close excess capacity. “Definitely this industry needs to consolidate. Our role will be (that) of an active player,” said Pesonen, head of the world’s third largest firm in the sector by capacity. “There will be swaps or share deals. We most probably won’t see any cash deals in this industry for the next year or two.” Norwegian newsprint and magazine paper producer Norske Skog’s chief executive Christian Rynning said the need for consolidation was clear, but said it would take time for big transactions to come. “It will probably take some time, until financial markets normalise and each company has cut capacity to sufficiently restore the market balance,” said Rynning. He said that Norske Skog, which has slashed its newsprint capacity by 23 percent in less than two years, did not have further plans for capacity cuts. Finnish packaging and paper producer M-real , whose sale last year of its graphic papers business to South Africa’s Sappi for 750 million euros was the biggest deal in years in the sector, said it also aimed to support further consolidation. “Our goal is to support consolidation of the European paper industry,” M-real chief executive Mikko Helander said. “No one can be satisfied with the European paper industry’s financial performance. Part of the difficulty is the industrial structure.” More paper recycling for Yorkshire Paper recycling capacity in Yorkshire, UK, has been increased by investment in waste management equipment by logistics specialist Potter Group. It means that an additional 32,000 tonnes of waste will be diverted from landfill over the next three years. The Potter Group has pur­chased a baler with help and funding from Resource Efficiency Yorkshire (REY). REY, a business support and market development delivery programme funded by Yorkshire Forward and the European Regional Development Fund (ERDF), pro­vided £54,000 to assist the Potter Group to purchase its new baler. Nick Brightey, general man­ager of the Potter Group, said: “Our new baler gives us the abil­ity to triple our processing capac­ity. As we can now process a variety of waste streams, we hope to gain more business from new and existing customers. “We intend to use the rail connection at our Selby site whenever possible. It is a resource that means we can offer our customers a 360­degree processing and shipping service.” Mondi orders vision systems from ISRA Mondi has ordered a number of web inspection systems for its coating lines in Europe from Aachen-based ISRA PARSYTEC. The two companies have been collaborating for six years, the experience of which led the paper and packaging group decided to sign an agreement outlining the delivery of several inspection systems which are to be integrated into production machines at various locations. “Innovative inspection solutions make it possible to lower our operating costs and to further improve the production quality. The new inspection solutions from ISRA PARSYTEC contribute greatly to these improvements,” Michael Stobl, operations director at Mondi Coatings, said. PAPER MAKING & DISTRIBUTION Industry News The forest industry is pioneering the bioeconomy I t will be difficult to achieve renewable energy targets without biorefineries because they are building blocks of the bioeconomy and, as such, boost prosperity and create a substantial amount of jobs. So says Antro Säilä, who manages the Business Environment and Innovation division of the Finnish Forest Industries Federation. And pulp mills are in effect biorefineries. “The renewable, recyclable and biodegradable products of the forest industry form a natural foundation for a Finnish bioeconomy. Next-generation biorefineries are a clear growth area and a new competitive advantage for the forest industry,” said Säilä, who was speaking at the Nordic Wood Biorefinery event held in Helsinki at the beginning of September. “Funding for commercial-scale biorefinery investments must be secured because the development of such large processes is an extremely extensive project for any single actor. We cannot take advantage of international backing, EU funding sources in particular, without national-level public investments,” Säilä said. “We must establish a functional market for transport biofuels in Finland in order to prevent these new products from seeking out other markets. It would be quite easy to transport liquid biofuels to the favourable tax climate of Germany, for example.” The entire value chain of raw materials and bioproducts must be made competitive in order to attract manufacturing of the industry’s new products to Finland, he said. The high cost of raw materials makes refining unprofitable. Energy policy and taxation must also provide support for the development of biorefineries. Biorefineries will diversify the utilisation of biomass, he said. “The forest industry has strong competence in the manufacture of renewable, recyclable and biodegradable products as well as suitable modern technologies for this. The networks, research resources and infrastructure that are required for innovation are likewise in good order. The role of public sector actors is to spur investment in biorefineries and to safeguard the functionality of the markets,” Säilä continued. “The development of new bioproducts is progressing gradually. One of the first steps is the manufacture of biodiesel on a commercially significant and profitable scale. This will provide resources and know-how for the development of new products and technologies, such as biochemicals and pharmaceuticals constituents.” Biorefineries produce biofuels and biochemicals as well as other biomaterials using wood and its constituents or other biomass as raw material. A pulp mill is already a biorefinery because, in addition to manufacturing raw material for paper and paperboard, it produces bioenergy and biochemicals. It is sensible to exploit wood biomass at biorefineries that are integrated with pulp and paper mills, concluded Säilä. Chemical recovery helps meet zero carbon targets at Kymi With low airborne emissions and high efficiencies, the newly-installed chemical recovery plant at UPM’s Kymi mill is close to meeting its zero carbon footprint targets. The 360 million euro plant, one of the biggest investments of its kind in Finland, was started a year ago. “Thanks to the new plant and by implementing energy efficient operation mode, we have a good opportunity to get very close to zero carbon footprint. This is a significant step towards carbon dioxide neutral paper making,” said general manager Timo Suutarla. “A few years back the making of a single ream – 500 sheets – of copy paper at Kymi produced the same amount of carbon dioxide as a few kilometres’ car ride. Now the emissions have decreased even further.” During the first year Kymi met all environmental permit limits for air emissions. Substantial improvements were reached instantly in sulphur dioxide, particle and malodorous gas emissions. The low air emissions result from a further developed evaporation and recovery boiler burning processes. The use of fossil fuels has also decreased. With the new recovery plant, the proportion of biomass based fuels in mill site’s energy production has soared to more then 90 per cent. Pulp prices raised by Södra Södra raised the price of its long-fibre and short-fibre pulp by US$40 per tonne in September. The new prices are US$730 per tonne for bleached softwood sulphate pulp and US$600 per tonne for hardwood sulphate pulp. Södra said the price increase is a result of the ongoing improvement in market conditions. “We currently have a situation with low inventory levels and are having difficulties delivering at the rate customers require. At the same time demand in Asia remains very strong,” said Ulf Edman, president of Södra Cell International. A s a leading specialist in thermal power generation and environmental technologies, AE&E Austria GmbH and Co KG (AE&E) has for many years provided engineering, supply, erection, commissioning and handing over of plants for various applications. But it is particularly proud of its reputation as a supplier of fluidized bed boilers. The pulp and paper industry has awarded many contracts to AE&E with companies such as Papierfabrik Palm GmbH, Kruger Inc in Bromptonville, Canada; M-real Hallein AG at Hallein, Austria; RWE Solutions (Tessag INA)/ZSG Stendal GmbH in Stendal, Germany, benefitting from its skills. Three years ago, Tembec Cellutions in France ordered an Ecofluid fluidized bed boiler from AE&E to replace its three increasingly inefficient existing boilers that were more than 50 years old. The investment was intended improve the efficiency of the mill, lower energy costs and reduce green house gas emissions. Tembec Cellutions is a leading producer of specialised speciality cellulose pulp and fluff for making nitrocellulose and cellulose ethers with a production capacity of 160,000 tonnes. Sold worldwide, its Biofloc range of pulps has been developed to meet the most stringent requirements of the chemical industry for the production of cellulose derivatives. The mill is located in Tartas, south of Bordeaux, near the Landes de Gascogne, the biggest cultivated forest in Europe, which provides the mill with sustainable source of wood. Erection of the Ecofluid boiler started in February 2007. With excellent project management and cooperation with the other companies taking part in the construction and start up of the plant, all project deadlines were achieved and commissioning was carried out earlier than expected. Started up in May 2008, the bubbling fluidized-bed boiler burns biomass from the industrial process, bark and other harvested wood residuals to produce 85 tonnes of steam per hour. Natural gas is only used for start-up. Scope of the supply contract included the bubbling fluidized bed steam generator together with the steel construction and cladding for the boiler house, an internal fuel dosing system, an ash system consisting of the mechanical ash discharge, pneumatic ash conveying systems and a sand silo. An electrostatic precipitator • TEMBEC TARTAS BIOMASS BOILER .with three fields (two in operation, one as spare) reduces emission to levels which are well below the prescribed limits. The boiler’s inauguration took place in June 2008, since when it has been operating successfully for more than a year. Ecofluid Technology Within the AE&E group, AE&E Austria is regarded as a centre of excellence for fluidized-bed combustion technology, offering both Powerfluid circulating fluidized-bed incinerator plants and Ecofluid bubbling fluidized-bed incinerator plants. Ecofluid technology provides precise temperature control of combustion through fixed ranges in the fluidized bed, in the combustion chamber and afterburner chamber, as well as the precise control of set values by means of injection of the required air volumes and flue-gas recirculation: The result is an outstanding burnout value as well as exceptionally-low emission values and high efficiency. Technical specification Fuel power: 74 MW Live steam flow: 93 t/h Live steam pressure: 46 bar (a) Live steam temperature: 423 deg C Heating value: 6-12 MJ/kg Biomass: Pine bark, wood waste from forest and saw mill and rejects of rejects of screening rooms More information from AE&E Austria GmbH and Co KG, Waagner-Biro-Platz 1, 8074 Raaba/Graz, Austria. Tel: 43 316 501-0. Fax: 43 316 501-482. e-mail: info@aee-austria.at Web: www.aee-austria.com Metso to rebuild Shandong Bohui Paper’s paper machine China’s Shandong Bohui Paper Industry Co is having the PM 3 machine at its Zibo mill rebuilt by Metso. Metso’s delivery includes two ValFlo headboxes. The 4.3m-wide (wire) machine produces gypsum board paper in the basis weight range of 140-210 g/m2. Shandong Bohui Paper Co, founded in 1994, is a large-scale joint-stock enterprise. The annual paper and board making capacity is around 850,000 tonnes. Tissue machine at Kimberly-Clark Salamanca mill to be rebuilt Metso is to rebuild the PM 1 tissue machine at the Kimberly-Clark SL Salamanca mill in Spain from November. The contract includes work on the existing dry-end section, which will be rebuilt with a Metso sheet support system, an Advantage TailThreader TIS tail threading system, an Advantage NipDeflector ballooning eliminator, an Advantage TailGlue system for tail turn-up, and an Advantage VacBox vacuum box system. A general reel upgrade and safety system implementation are also included in the delivery. Kimberly-Clark is a leading global health and hygiene company employing nearly 53,000 people worldwide and posting sales of $19.4 billion in 2008. Integrated production line for DongHae in South Korea Moorim Paper Group has ordered an integrated paper production line for its DongHae pulp mill site in Ulsan, South Korea from Voith. The line will make wood-free coated, machine-finished coated and wood-free uncoated paper grades. It will use pulp made at the site, enabling Moorim to be the first integrated pulp & paper mill in South Korea. The new DongHae PM 1 is based on the One Platform Concept with a wire width of 9,300 mm and a design speed of 1,500 m/min. The machine is designed to produce fine papers in a basis weight range of 75 to 150 g/m² with an annual output of about 450,000 tons. Start up is scheduled for spring 2011, when Moorim Paper Group’s overall production output for fine paper will rise above 1 million tons, making the company the biggest fine paper producer in South Korea. This also includes the output of the already existing fine paper production lines of Jinju mill (PM 1 to 3) and of Daegu mill (PM 1 and 2). Tissue machine to expand CPMC capacity in Mexico CMPC Tissue, Latin America’s second largest tissue paper manufacturer, has bought a 5.6m-wide machine for its Absormex subsidiary plant in Altamira, Mexico, from Voith. The design speed will be 2,000 m/min, with a 220 t drying capacity per day. The start-up is scheduled for the second half of 2010. Equipment will include the approach flow, the MasterJet II T headbox, a Crescent Former, the press- and drying section with a Voith Paper Air Systems hood and a ribbed Yankee cylinder, the erection as well as the start-up and commissioning services, in addition to the engineering required for the project. CMPC Tissue is the tissue business of the Chilean pulp and paper Empresas CMPC group. In 2008, the company’s sales were US$870 million. Speed increases at Pindo Deli in Indonesia Uncoated paper line at MCC Paper Yinhe starts up Shandong Huatai Corporation is planning to improve output in its fast growing wood pulp production lines using automation systems from ABB. A Displacement Digester System (DDS) from Chemical and Pulping Ltd (CPL) at the Rizhao Huatai mill that produces pulp made out of fast-growing wood will have an 800xA installed by ABB China Process Automation. The DDS will help the mill’s fast growing wood production achieve a ‘4-high’ – high usage rate of energy and chemicals, high pulp conversion rate and high production efficiency. The Pulp and Paper BU of ABB China Process Automation will also supply accompanying automation, systems and engineering services. “The strong union of ABB technology throughout the world by upgrading production efficiency, raising the pulp yielding rate and reducing use of steam and chemicals,” says Lin Shuming, head of ABB Pulp & Paper North Asia. ABB’s award-winning 800xA provides paper mills with improved productivity and profitability. The 800xA extends the scope of mill control systems to include all automation functions in a single operations and engineering system. • ABB has also supplied an Industrial IT System 800xA at Sun Paper‘s Shandong Mill in China. It is intended to improve the output the mill’s new fine paper machine PM23, supplied by Metso. Once operational, the new line will increase the mill’s capacity by 300,000 tons of uncoated fine paper per year. Fabrica De Papel San Francisco starts up tissue machine in Mexico An Advantage DCT 100 TS tissue machine supplied by Metso came on stream at Fabrica De Papel San Francisco in Mexicali, Mexico, in June. The project comprised a complete tissue machine equipped with an OptiFlo II TIS headbox, a 16-foot Metso Yankee cylinder, an Advantage AirCap yankee hood, sheet control, tail threading equipment and an Advantage SoftReel P reel. The design speed of the 2.6-m-wide tissue machine is 2,200 m/min. “We are extremely satisfied Shandong Huatai’s PM 8 paper machine gets chemical systems from ABB A coating-colour kitchen, wet-end chemical delivery systems and a waste water treatment unit are being supplied by ABB to Shandong Huatai Paper Co at Dawang City, Shandong Province in China. The project will be delivered by ABB Process Automation Division, Chemical Delivery Center of Excellence (formally Cellier) located at Aix-les-Bains, France. The supplied systems will with the performance of the machine during start-up,” said plant manager Darío Palma y Meza Espinoza. “The machine climbed the start-up curve very smoothly and efficiently. Just 12 days after the start-up it was making saleable paper at 2,100 m/min without any difficulties. This is certainly our best start-up ever.” It is the second such machine at the mill, the first of which was installed in 2006 and set a speed record for tissue production earlier this year with an average speed of 2,160 m/min for 24 hours. be used on Shandong Huatai’s PM 8, its newest paper machine. The new 8.1m-wide PM 8 will produce 500,000 tons per year of coated and uncoated fine paper with a design speed of 1,800 m/min for the paper machine and 2,000 m/min for the coater. Since 2001, ABB has been the chemicals delivery system supplier to Huatai Group for their PM 10, PM 11, PM 12 and PM 6 projects. Indonesia’s Pindo Deli mill in Karawang has converted its PM 5 standard rubber covered suction press roll with 29.57 per cent open area to Voith's SolarSoft polyurethane cover with a suction, blind-drilled and grooved surface design, which has 45.6 per cent open area. “The improvement of open area significantly improved the dewatering capacity and has immediately led to a 5-20 per cent increase in machine speed dependent on the tissue grade,” said production manager Usep Saepul. “This change is a major move forward leading to a production increase of between five and 12.7 tons per day dependent on the grade of tissue.” SolarSoft is the latest generation in polyurethane covers of the Voith Paper Rolls Solar series. It is specially developed for suction rolls and pressure rolls of tissue machines. An uncoated papermaking line at MCC Paper Yinhe Co in China came on stream in July. The 200,000 metric ton capacity 5.8m-wide line at Linqing city in Shandong province was supplied by Metso. “This is the first modern fast-speed paper machine line for our company and we are happy that the machine was successfully started up as planned even though the schedule was tight,” said Wan Zhonghua, executive vice general manager at MCC Paper Yinhe. “Cooperation between Metso and Yinhe has always been good. Now the machine speed is 1,250 m/min. Given that production has been running less than two months since start­up, our quality still needs to improve but we believe that with Metso’s professional support we will reach our target.” MCC Paper Yinhe is state-owned and runs two mills in Linqing city with about 6,000 employees. The company was originally founded in 1958 and joined MCC in 2007. MCC (China Metallurgical Group Corporation) is one of the largest equipment manufacturers in China. ABB focuses on new QCS technology This new sensor, the latest in ABB’s 50+ year history of pioneering online paper quality measurements, finally provides papermakers with the precision tool to measure and control caliper even on the most demanding paper grades. To find out more, contact your local ABB Account Manager and visit www.abb.com/pulpandpaper © Copyright 2009 ABB. Dow Corning PAPER MAKING & DISTRIBUTION In the pulp and paper making industry, Dow Corning is perhaps best known for its range of silicone-based products which offer a number of important physical characteristics for pulp washing, including excellent application, wet-out, thermal stability and broad compatibility with a wide range of other paper chemicals. And it is not just providing technology for new applications, such as antifoams for papermaking and paper coating, digester aids, stickies control technology, and tissue softeners, it is enhancing the way in which the company serves its customers’ innovation through collaborative development. In addition to the innovative specialty products, Dow Corning now also offers standard silicones for the paper market through its Xiameter online business. Dow Corning’s Pulp and Paper team is part of the company’s Advanced Interface Market Business, which is lead by Jeremy Burks, its global executive director, who recently moved from Korea to China, where he is also the vice president of Dow Corning’s speciality chemicals business in that region. British born with a degree in materials science and technology, Jeremy Burks has been with Dow Corning since 1987, working initially in sales for the automotive and electronics industries. In 1993 he moved to Belgium as Economic Evaluator / Business Controller for Europe and then became Global Planning and Evaluation Manager for the Designed Products business. Burks tries to get home as much as possible to see his family in Devon and if possible catch a game of rugby. PMD magazine asked him about the services that Dow Corning offers the pulp and paper industry. Q: Describe the scope of the Advanced Interface Markets Business and the nature of the products and services offered to the paper and pulp industries. A: “This business unit covers many different areas of our work – from coatings and inks, textiles; pressure sensitive industries, paper and pulp, performance chemicals, oil and gas, reinforced plastics and tires. “Just looking at paper, we’ve been a leading supplier of silicones to the pressure sensitive industry since this technology surfaced in the early 1950s. Our portfolio of release coatings is pretty comprehensive – naturally it’s expanded over the years as we’ve worked closely with customers to develop some new innovations for them in paper and paperboard. “Our primary product line now is our solvent-free coatings – these include emulsions and platinum, rhodium, and tin catalyzed options based on different polymer technologies. “Over the last 15 years, we have expanded into other areas in the paper industry and have an extensive range of applications for our materials in pulp production and in paper making and finishing. The role of our materials in this market is to improve the efficiency and sustainability of the manufacturing processes as well as improving the properties of the paper produced.” Q: What is the turnover in the AIM Business and its profit contribution to Dow Corning and how has it been growing? A: “These segments offer some of the most exciting growth opportunities within Dow Corning’s diverse business portfolio. Unfortunately, as a privately held company we don’t disclose information about the contribution each of our businesses makes to our overall company results. But suffice to say – this segment is a great match for Dow Corning.” Surface specialists New ways of specifying the innovative products and services that can enhance the performance of pulp and paper making lines have been introduced by Dow Corning. PMD magazine talked to its global chief responsible for our sector JEREMY BURKS AND WOOTEAK JUNG, GOVERNOR OF CHUNG-BUK STATE, AT THE DOW CORNING LED SILICONE FACILITY OPENING AT JINCHON IN CHUNG-BUK STATE, KOREA Q: Within the pulp manufacturing, tissue manufacturing and paper recycling sectors which products are most popular and provide the highest turnover? A: “Within these sectors, products for use in pulp manufacturing (brown stock washing process) represent the most significant part of our business. At the same time Dow Corning products for paper recycling and tissue enjoy much faster growth dynamics.” Q: What are the regional strengths in this business? A: “In terms of our involvement in pulp, Dow Corning is a truly global company and we’ve been growing our presence in emerging and developing countries including China, ASEAN, India, CIS and Latin America. One important element is our ability to tailor our materials and products to suit different situations around the world. “For example, we tailor and test our products to ensure they perform in pulps of new evolving commercial wood species, like Eucalyptus and Acacia as well as in the ‘traditional’ Northern wood species. Having a Dow Corning presence in those growing regions to provide expertise and support is critical because of the growing shift from Northern fibers to Southern fibers. “Looking at the pressure-sensitive industry, we see this as a very local business with most of the materials used close to the point where the manufacturing takes place. Dow Corning is following our customers into these geographic growth areas with significant activity in Greater China and Korea. Q: How do the products and services from Dow Corning improve the quality of the product and the productivity of a paper making line? A: “Silicones generally have a wide variety of qualities that help improve the performance of other materials. Specifically for paper, our materials make a big contribution in areas that are important to the paper making industry. “For example, cleaner pulp, better drainage and higher pulp output, softer tissue, brighter recycled fibers, process environmental safety and smoother process run-ability. Our products are generally chosen because their high performance delivers lower cost-in-use. “Dow Corning release coatings have allowed many improvements in the pressure sensitive industries business. So for example, today we no longer have to lick stamps before putting them onto an envelope – we can just peel and press them. Much quicker and they don’t leave that horrible taste in your mouth! Our technology has also made it possible for clear labels to be applied to glass products.” Q: What has been the evolution of the various processes in which the AIM Business has had most influence? A: “I think we’ve been very successful in listening to what our customers are telling us, understanding how their needs are changing and then adjusting our own materials and services, which include helping to make our customers or their products more efficient or sustainable.” “In pulping and paper making, we work with business partners who service the mills. Our role has been to develop new technologies that cope with variations in the process (changes in the input raw materials for instance) and improve the process rates. We have also been adding new functionality for the finished paper such as softening of tissues.” Q: Has the global economic crisis, which has particularly hit the paper industry, impacted Dow Corning’s business? A: “The paper and pulp markets haven’t been immune from the economic downturn – like most business sectors it slowed at the end of last year and in the first part of the year. Dow Corning has been through a number of economic downturns and challenges, and is well positioned to weather this storm. Not surprisingly, many businesses have been operating on a ‘Cash is King’ priority and looking hard at efficiency improvements. It’s something we’ve been really conscious of – our expanded Xiameter brand is one of the ways we’re working to help improve efficiency for our customers. Q: How do you view the global paper industry in five years time? A: “The paper industry has seen overall lower growth due to the shift to electronic media and the growth of the plastics industry. Dow Corning however sees opportunity for a rebirth in the paper industry five years down the road because of the growing focus on sustainability which will demand further innovation to achieve.” “It’s something we’ve seen increase in importance over the last few years as we’ve talked to our customers. We’ve certainly recognised the importance of this within our own company and see this as one area in which we’ll be putting more emphasis in the future. “Within our business, one of the growing needs is around the ability to develop sustainable paper and processes that truly capture the sustainability, renewable resource, and environmentally friendliness of ‘sustainable’ paper versus plastics and non-recyclable paper products.” More information from Dow Corning Corporation, Corporate Center, PO Box 994, Midland, Michigan 48686-0994, United States. Tel: 1 989 496 7881. Fax: 1 989 496 6731. JEREMY BURKS AT THE KOREA STANDARD ASSOCIATION CHIEF EXECUTIVE OFFICERS’ BREAK­FAST MEETING IN 2008 WHERE HE WAS A KEY SPEAKER PAPER MAKING & DISTRIBUTION Product news Forklift trucks with performance and economy options Space saving safety controller from Pilz E lectrically-powered fork lift trucks with a range of features that include performance or economy settings and an ability to operate in small areas have been launched by Yale. The VG cushion tyre series from Yale follows the launch of its VT and VF series and is the latest in its NexGen product programme. Available in lifting capacities from 2,200kg to 3,500 kg, the VG series is generally used in internal applications where lifting capacities are in excess of 2,000kg and space to manoeuvre is at a premium. All the features introduced on the VT and VF models are incorporated into the VG series with the focus on productivity and ergonomics. Operator settings include the HiP mode, in which the truck delivers high acceleration, and the eLo setting, providing energy efficiency, enabling the truck to operate for longer periods HEAVY LIFTER WITH A LUXURY SPECIFICATION between battery charges. highest setting provides Other settings include four maximum speed and performance modes, where the acceleration and the lowest mode is used where the application demands very precise load handling and manoeuvrability. Comfort is enhanced by the Accutouch mini lever module which features cushioned arm and palm rests with fingertip control of levers. These features are considered to be a major contributor in reducing repetitive strain injuries (RSI). Features on the VG used on luxury cars include an automatic park brake. This increases productivity where the driver is frequently moving on and off the truck. It also removes the need for alarms and buzzers alerting operators that the handbrake has not been set. Dashboard space is provided for clipboards, pens, mobile phones and drinks. A 12V power socket can be fitted as an option for the recharging of production equipment and personal items, including mobile phones or mp3/4 players. More information from www.yale-forklifts.eu A small multifunctional configurable safety controller for applications up to BS EN ISO 13849-1 Ple and BS EN 62061 SIL 3 has been launched by Pilz Automation Technology. Measuring 45mm wide, the PNOZmulti Mini features all of the usual safety monitoring functions of the established PNOZmulti with additional benefit of an LCD display for status information and diagnostic messages. Together with the new low-cost ‘lite’ licence for the PNOZmulti Configurator Software, Pilz now offers a cost-effective start-up option for applications requiring three or more safety functions. The first PNOZmulti Mini model, the PNOZmm0p, is multifunctional, program­configurable and designed to replace from three to five traditional safety relays. The controller performs monitoring of safety functions such as Emergency Stop Switches, Guard Interlock Switches, Safety Sensors, Light Curtains and other safety devices, plus the same unit can execute standard (i.e. non-safety) control functions. Even with its more compact design, the PNOZmm0p offers 20 safe digital inputs; four safe semiconductor outputs (capable of being configured up to SIL3, PLe) and a USB configuration interface. More information by email from technicalsupport@pilz.co.uk, telephone 44 1536 460766 or visit www.pilz.co.uk. PILZ AUTOMATION TECHNOLOGY IS LAUNCHING THE PNOZMULTI MINI MULTI­FUNCTIONAL CONFIGURABLE SAFETY CONTROLLER. PAPER MAKING & DISTRIBUTION Product news New quality information software was recently installed at Smurfit­Kappa’s Townsend Hook Mill in Kent, UK, by QISoft. The project was driven by the need to replace an outdated system and an increasing need for connectivity, real time information and reporting of performance data to support the efficient running of the mill, said QISoft. Smurfit-Kappa’s project team, led by product development engineer Swapan Bhattacharjee, reporting to operations director Geoff Brooks, drew up a full set of requirements and was responsible for commissioning the software. QISoft describes the QISv6 software as a high performance, distributed information management system which provides a ‘single window’ view of operational data from a variety of data sources. It was selected for its functionality, customer support and the backing provided by QISoft, who have extensive knowledge of the paper industry. The SQL-based database application is deployed at Townsend Hook on a Citrix Terminal Server and has been installed in the production, technical and laboratory areas of the mill. Tim Perris, QISoft business manager, commented, “Following the success of QIS at other Smurfit-Kappa mills in the UK and South America, we welcome the addition of Townsend Hook. Using the array of analytical and reporting tools within QISv6, Townsend Hook can enhance process understanding to deliver excellent product and service to their customers.” More Information from QISoft Limited, Alexander House, Station Brow, Leyland, Lancashire, PR25 3NZ, UK. Tel: 44 1772 421442. Fax: 44 1772 641155. E-mail: info@qisoft.com Web: www.qisoft.com Improved quality information software installed at Smurfit-Kappa HOW QISOFT'S QISV6 QUALITY INFORMATION SOFTWARE LOOKS ON SCREEN To view this magazine online visit: www.pmdmagazine.com Innovation out of tradit A new curtain coater from Andritz has expanded the specialist paper portfolio at the Cham Group in Switzerland. PMD reports P aper has been manufactured in the small town of Cham, in Switzerland, for more than 350 years. This long tradition is the basis for vast knowhow generated at the Cham Paper Group (CPG) which has three production plants in Switzerland and Italy, five paper machines with a capacity of 250,000 tonnes and has been recently been focusing on manufacturing papers with specific properties. Sales are about CHF300 million (US$289m) a year “Paper is being used in more technical applications than most people are aware of,” explains Dr Peter Müller, plant manager and member of the management at the CPG. “Did you know that paper is used even in the production of auto licence plates?” He is well versed in this subject because, in this area, Müller claims to be the world market leader. Another specialist sector is the base paper for adhesives. What happens when the paper quality is poor? Usually in tears when the foil is removed to create ugly blobs, wrinkles and blisters on the label. Just imagine a police car with blistered and wrinkly coloured graphics on its surfaces. It’s not just in Switzerland this would be unacceptable. And what is important to police cars also is important to containers, trailers and transporters, where today’s market often requires changes such as a new logo, new lettering or a new publicity scheme to be affixed. There are many more examples for the use of paper in this area of business alone. The concentration on specific applications is far from incidental. “We are looking for areas that show medium to long-term development potential,” says Müller, who holds a doctorate in chemistry. “Years ago we had already realized that the development of the digital printing technology was just beginning. Today the knowhow regarding the complete process is so comprehensive that CPG employees even function as consultants in the development of special printing software.” Digital printing, however, is only one field that shows possibilities for growth potential in Cham. Müller believes the areas of labels and flexible packaging are just as important. Here the replacement of plastics in certain applications is particularly important. “Today we are able to offer paper for flexible packages which in their properties can be compared to plastics,” says Müller. “But contrary to plastics, foil paper can be manufactured using renewable resources and is, even where stringent government regulation does not penalize the use of plastics, a better alternative. This is why we are especially developing new papers to attain certain properties of plastic foil even with paper.” In this area, as in the field of digital printing, curtain coating is an important ingredient for further development, Müller points out. This is particularly relevant for the finishing of paper with coatings that are designed to produce special chemical or mechanical properties. The potential of applying several layers in a contour coater at the same time makes this process technically and economically very intriguing. As a result an investment was recently made in a curtain coater from Andritz BMB. The new machine is characterized by high flexibility. It can produce in-board and over-board (with or without edge) on the coated sheet. In addition, the curtain height and angle of inclination can be adjusted independently. Müller and his colleagues want to operate the Coating Machine 5 not merely as a production line, but use it systematically for testing new products in an industrial environment. That is why, in addition to the three blade coating units, a multi-layer cascade nozzle has been integrated in the PrimeCoat Curtain. The two slots are capable of applying different, water-based media in a two-layered curtain simultaneously. This is an absolute must, especially for innovative products, says Müller. The adjustment range is infinitely adjustable by motor and allows for coating widths between 3,020 and 3,280mm. The curtain can be set up at different heights (200 to 350mm); its angle of impact can be inclined by up to 10 deg. Grammages between 60 and 200g/m2 are processed at speeds between • .200 and 750m/min. The coater line design speed is 1,000m/min. The Coating Machine 5 restarted operation in March 2009. “We are the experts for special functionalities,” says Müller. The Cham Paper Group also manufactures the raw paper which, as a matter of course, contributes significantly to the end product. But at the end of the day it is the coating which makes the difference, and here lies the Group’s essential competence. It has guaranteed them success in a stable niche. “And this,” Müller is convinced, “will be strengthened substantially with the new Curtain Coater.” More information from Cham-Tenero Paper Mills Inc, Fabrikstrasse, CH-6330 Cham, Switzerland. Tel: 41 41 785 3333. Fax: 41 41 785 3150. Email: mail.cham@cham-group.com Facts & Figures Coating Maschine: Paper grades: Basis Weights: Coating unit: Web width: SM 5 graphic and technical papers, labels and packaging papers 60 - 200 gsm Prime Coat Curtain 3.060 - 3.280 mm Coating width: Sheet Tension: Production speed: Design speed: Media: Start-up: 3.020 - 3.280 mm 200 - 600 N/m 200 - 750 m/min 1.000 m/min coating colors 2009 Products Basis papers for the self-adhesives industry • clay-coated silicone raw papers (labels in rolls, EDP and sheet laminates, self-adhesive PVC foils • glassine silicone raw papers (labels, technical applications) • coated label papers (matt to high-gloss grades) Papers for flexible packaging • coated kraft papers (customised for laminating and coating) • oil and grease repellent papers (manufacturing of sacks and bags for foodstuffs and pet food) • satinated kraft papers (wrapping paper for sweets) • uncoated silk and kraft papers (laminated, coated or paraffinised, e.g. as fast food wrap or for the production of bags) Technical papers • innerliner papers (also metallised, e.g. for the tobacco industry) • crepe raw papers (cigarette filters) • wet glue labels (beverage industry; with oil/grease barrier also for the foodstuffs industry) • thermo transfer papers • base papers for metallisation • special papers for cast film production • carrier papers for decal pictures (ceramics industry) Inkjet papers • surface-treated inkjet paper (high whiteness, good line sharpness, high colour density, high water resistance) • graphic papers (various coating versions) • papers for solvent- and oil-based printing (for all current plotter systems) • wet strength/water resistant and for backlighting (outdoor advertising) • sublimation papers Safety in numbers There’s much more to maintenance, spares and overhaul management services than just supplying parts at the right price. PMD reports A s one of Europe’s leading suppliers of maintenance, repair and overhaul (MRO) products and services, Brammer is an approved distributor for the leading engineering component manufacturers in bearings, seals, motors, gearboxes, mechanical power transmission, hydraulic and pneumatics, tools, personal protective equipment (PPE) and general maintenance products. The company works with some of the biggest names in the paper making industry in Europe and this experience gives Brammer an unrivalled understanding of the specific needs of companies involved in the manufacture of pulp and paper. In particular, the company is well aware of the impact of factors such as wet environments, high sustained speeds and high temperatures on maintaining production uptime. Brammer also understands how wider issues such as spare part availability, health and safety, sustainability, and the need to conserve energy at every opportunity, impact on the MRO requirements of companies in the paper making sector. All of that experience is applied by Brammer to provide the very best in MRO support, but its services go a long way beyond simply delivering the right part, at the right price and on time. More than anything, the company understands the commercial pressures on paper manufacturers to drive down costs while optimising production efficiency. Brammer offers a range of proven solutions to optimise maintenance and stores operations, deliver improved production efficiency, eliminate expensive downtime and reduce costs. Added value services such as predictive and preventative maintenance programmes and condition monitoring improve production line efficiency and minimise downtime, while audits of energy usage and compressed air equipment are proven to reduce costs through helping to reduce energy bills. Brammer can also improve maintenance spares management through a range of managed and site-based services, including the provision of a Brammer Insite – effectively a branch of Brammer in your plant. This offers customers the benefits of best-practice inventory management, designed to optimise product availability and maximise plant uptime whilst at the same time guaranteeing the quality and continuity of plant critical spares. Working with Brammer can also help to reduce purchasing and supply chain costs and complexity. Whether streamlining processes to reduce administration and transactional costs, rationalising the supplier base or standardising parts to reduce purchases, stock and the risk of downtime, all of these services will help to eliminate risk from the supply chain for plant critical spares and reduce working capital through improved spares management. Brammer is the UK division of Europe’s leading distributor of industrial, mainte­nance, repair and overhaul (MRO) products and services. With sales of £123 million and more than 800 employees, the company offers a range of over one million individual products via a nationwide network of 89 Sales and Service Centres. Brammer’s extensive product range covers bearings, mechanical power transmission products (including gear- All about Brammer boxes and motors), pneumatics, hydraulics, seals, industrial automation as well as a complete range of tools, maintenance and health and safety products. The company is an authorised distributor for many of the world’s lead­ing brands including SKF, NSK, Renold, Gates, Flender, Siemens, SMC, Norgren, Festo, Rocol, Loctite and Schaeffler UK. By combining technical expertise with excellence in supply-chain logistics, pur­chasing and the management of third-party providers, Brammer has a proven track record of saving its customers money within three critical business areas: reducing total acquisition costs, improving overall production efficiency, and reducing working capital. More information from Brammer European Operations Support Centre, 43-45 Broad Street, Teddington, Middlesex, TW11 8QZ, United Kingdom. Web: www.brammer.biz BrammerPAPER MAKING & DISTRIBUTION More than eight out of ten manufacturing companies in Europe regard the authentication of the maintenance, repair and overhaul (MRO) products they use as important, according to a survey by Brammer, Europe’s leading MRO products supplier. Yet a recent discovery of 30 tons of counterfeit bearings in the Czech Republic shows the scale of the threat to the European manufacturing industry and the importance of authentication to those working in the sector. In its survey of more than 330 manufacturing companies across 10 countries in Europe, Brammer found that the risk of using counterfeit products is so great and the impact so threatening that 84 percent of those questioned rated the authentication of the MRO products they use as ‘important’ or ‘very important’. Brammer believes that it has an important role to play not only in minimising the risk of unknowingly purchasing counterfeit goods, but also in offering prices and lead times that compete with those dealers selling counterfeit products to unwary purchasers. The Czech haul of 30 tons of counterfeit SKF bearings from an unauthorised distributor in the North East of the Czech Republic; was one of the biggest in Europe. Radek Sulta, managing director of Brammer in the Czech Republic comments: “Counterfeit products have been a serious problem over the last few years, and it is easy to find dealers selling products from dubious sources, perhaps offering a better lead time and some small cost saving; but at what real cost? It is our job to highlight the issues around counterfeit goods and to provide a guaranteed purchase source as an authorised distributor.” Identifying counterfeit products can be very difficult and while there are many technological innovations to prevent counterfeiting, increasingly these are being replicated by counterfeit manufacturers making them harder to spot for the purchaser. The best way to eliminate the risk of being a victim of the MRO product counterfeiters is by only using an authorised distributor accredited by the manufacturer. SKF, along with other manufacturers, strongly advocates this approach and works closely with its authorized distributors including Brammer to protect its brand and its end users. . “Ensuring our customers receive the best quality products is always imperative for us,” said Ian Fraser, chief executive of Brammer, “and remaining alert for counterfeit products is a key part of this. We know that with our in-depth product knowledge and strong relationships with the manufacturer we can help to identify counterfeit products and ensure that they do not reach our customers. “But we also want to work with our customers to help them reduce lead times, increase their cost savings and improve their MRO procurement in longer lasting ways, so that they can continue to save time and money in the future, while avoiding all the risks involved in buying from unauthorised dealers.” Counterfeit bearing haul highlights risk of not using authorised suppliers IAN FRASER, CHIEF EXECUTIVE OF BRAMMER Heimbach PAPER MAKING & DISTRIBUTION With energy expenditure accounting for up to 35 per cent of total manufacturing costs on a paper making line, pulp and paper producers have always had a strong incentive to improve energy efficiency. In recent times increases in energy costs have focused the emphasis on conserving energy. Whilst it is an energy-intensive industry, pulp and paper producers have made significant progress in energy conservation in recent years. Primary energy consumption has been reduced by about 16 per cent and specific electricity consumption is down by about 11 per cent. The average energy use per tonne of product is now around 16 GJ (Gigajoule) – significantly less than the 24 GJ required in 1990. It is commonly accepted that the dryer section of a paper machine is the largest consumer of energy. However, opportunities to optimise and conserve energy in the forming section exist and are often overlooked. Figure 1 highlights the energy used by each section of a typical paper machine. Most of the energy used in the forming section is based on electrical power. Figure 2 highlights the distribution of electricity consumption in the forming section of a typical newsprint machine. Clearly, the areas of focus to save energy in the forming section are in the vacuum and drive systems. Detailed in this article are two case studies that demonstrate how it is possible, through former and forming fabric optimisation, to save energy in the forming section. Practical ways to save energy in the forming section 1. Optimisation of vacuum setting The vacuum regime on all paper machines is one of the key aspects in controlling and optimising the ex-couch dryness. The main task in the forming section, after the dryness has reached 5-6 per cent, is to maximise the dry content to the pick-up. The advantages of graduating vacuum can be summarised as follows: Higher sheet consistency: Entering the couch at higher consistency improves runnability by presenting an inherently stronger sheet. Less energy is needed in the presses. Reduction of drag load and increased fabric life: Since water is gradually being removed over the HiVac units, the fabric is continually lubricated, which reduces drag load and fabric wear. Improvements in sheet quality: Graduated vacuum normally reduces pinholes and overall marking, whilst increasing fines/filler retention. Decreased energy consumption: Vacuum optimisation can reduce overall vacuum requirements and hence energy consumption. A recent case study is presented which highlights the significant opportunities to increase dryness ex-couch and reduce energy through vacuum optimisation and reduction. Case Study – vacuum setting The objective of the trial was to optimise the vacuum to gain the maximum increase How forming fabrics can reduce power consumption Significant energy savings can be made on a paper making line by tuning the vacuum settings and by making the correct choice in forming fabrics. Ged Leigh* explains how and provides examples FIG.1 ENERGY CONSUMPTION OF PAPER MACHINE FIG.2 DISTRIBUTION OF ELECTRICITY CONSUMPTION IN FORMING SECTION in dryness whilst keeping the formation at a similar or better level whilst reducing power consumption. The particular machine (shown in Figure 3) produces SC-A grades at around 1,100 m/min. The initial approach was to review the standard vacuum and dryness conditions by means of on-machine measurements (as shown in the ‘Standard’ data points in the Figures 4-6). Heimbach specialists then carried out the subsequent changes to the standard vacuum settings, documented in trials 1-3: The initial vacuum (HiVac 1) was reduced and a graduated approach was implemented through the trials (as in Figure 4) to gain the FIG.4 VACUUM SETTING highest dryness and lowest drive amps. Figures 5 and 6 show the results of the changed vacuum settings. The best results were achieved in trial 3 where it was possible to reduce the overall vacuum by 2 per cent (Figure 4) which subsequently reduced the drive power consumption by 6 per cent (Figure 5). At the same time the pre-couch consistency increased by almost 1 per cent (Figure 6). These achievements demonstrate that a correctly-designed and operated table will reduce power consumption and thus energy costs. Table optimisation can offer significant benefits with minimal investment: meaning the return on investment can be high. The prerequisite to this success are forming fabrics which meet all of today’s requirements, from highest retention to maximum dimensional stability. By fulfilling all of these requirements Heimbach forming fabrics have contributed to the above-mentioned success. 2. Reducing drive power consumption While this case study clearly demonstrates that by means of vacuum optimisation a paper maker can save power consumption, there are further opportunities for energy reductions, such as with the influence of forming fabric materials on the energy consumption of drive components. The comparison between the usual alternating polyester/polyamide weft monofilaments (CMD) and the 100 per cent Duralon wefts in forming fabrics from Heimbach is summarised in the following: Duralon fulfills the key criteria of today’s and tomorrow’s forming fabrics with low coefficient of friction, good abrasion resistance and high dimensional stability. Case Study – drive power In this study the paper machine with a twin­fourdrinier former produces packaging board, testliner and fluting at around 600­1,000 m/min. The machine had recently been rebuilt in order to increase production speed and quality. Heimbach was chosen as the start-up supplier with standard 16­shaft DL EWA+Primoplan.HD in the bottom position and a 24-shaft SSB Primobond.F in the top position, both containing Duralon. After running the machine for 18 months it was noted that the power consumption of the drive components was• FIG.3 VOITH DUOFORMER HMS FIG.5 ELECTRICITY POWER OF DRIVE COMPONENTS significantly reduced when running Heimbach fabrics. The reason was that compared to the polyester/polyamide wefts of the usual fabrics the Duralon­containing fabrics have a significantly lower coefficient of friction. Additionally, as an additional benefit, it was possible to increase the machine speed by an average of 27 m/min. The following comparative calculations for the bottom position are based on the maximum power capacity of couch and forward drive roll each being 315 kW, for a total capacity of 630 kW. The drive load of the polyester/polyamide fabrics has been measured at 90 per cent, of the Duralon fabrics at 60 per cent. The paper weight produced was 135 gsm; the speed was 841 m/min whilst running polyester/polyamide fabrics, increasing to 868 m/min with Duralon fabrics. FIG.6 PRE-COUCH DRY CONTENT Comparative calculation of cost to drive Cost to drive with Polester/Polyamide fabrics (Competition) • 630 kW (max. capacity) x 90 per cent (drive load) = 567 kW (drive load) • 567 kW x 24 hours x 350 days x 0.07 EUR/kWh = 333,396 euros/year Cost to drive with Duralon fabrics (Heimbach) • 630 kW (max. capacity) x 60 per cent (drive load) = 378 kW (drive load) • 378 kW x 24 hours x 350 days x 0.07 EUR/kWh = 222,264 euros/year The annualised saving shown amounts to more than 111,000 euros only by reducing the drive load with Duralon fabrics, this being achieved with a 3 per cent speed increase of 27 m/min. The resulting increase of production is presented as follows: Production with polyester/polyamide fabrics (competition) • 135 gsm at 841 m/min = 17.10 t/h x 24 hours x 350 days = 143,640 t/year Production with Duralon fabrics (Heimbach) • 135 gsm at 868 m/min = 17.65 t/h x 24 hours x 350 days = 148,260 t/year The 3 per cent production increase of 4,620 tons per year at 370 euros/t amounts to a sales value of 1,709,400 euros. Summary Clothing costs are relatively low compared to the potential energy savings and production increases that can be achieved with modern, correctly applied forming fabric designs and materials – clearly FIG.7 MAIN DESIGN DRIVERS OF DURALON demonstrated in the above case studies. The total PMC cost is approximately 2 per cent of the total operating costs of a paper machine – a small number compared to the 35 per cent required for energy expenditure! Forming fabrics have a greater effect on final properties than press and dryer fabrics but less effect on energy consumption. However, through optimisation of the former elements and correct application of forming fabric designs and constituent materials, significant energy related benefits are achievable. * Ged Leigh is Strategic Product Manager (Forming) at Heimbach GmbH & Co. KG, An Gut Nazareth 73, 52353 Düren, Germany. Tel: 49 2421 802-0. Fax: 49 2421 802-7 00. email: ged.leigh@heimbach.com web: www.heimbach.com New twists in hydrocyclones Simplification of the pulp cleaning process by using higher consistencies has lead to improved quality at at Mondi SCP’s Ružomberok Mill. PMD reports I mprovements in the quality of pulp have been achieved at Mondi SCP’s Ružomberok Mill in Slovakia since the installation of a Celleco Twister hydrocyclone system from Finnish-based GL&V. And that has enabled the plant, which is part of the Mondi Europe & International Division, to expand its supplies of pulp to other customers as well as raising its paper quality. Part of the global Mondi Group, the Mondi Europe & International Division has around 95 production plants in 30 countries and approximately 28,000 employees producing corrugated paper, bags and specialities and uncoated fine paper. Mondi SCP has three paper machines with a capacity of more than 180,000 tons of offset paper and 330,000 tons of office paper. The modern history of pulp production in Ružomberok started in 1981 since when capacity has risen from 600 t/d to 1,450 t/d of hardwood and 750 t/d of softwood pulp. Over this period, the equipment has been modified to increase production and significantly reduce the environmental load. With increasing requirements for improved brightness and impurities, a major modernisation of pulp production was launched at Mondi SCP in 2006. In 2007, Celleco Twister technology for pulp screening, before the drying section, was introduced, through which the mill managed to achieve standard quality, as measured by impurities, for its commercial pulp. The extension of the bleach plant with a hydrogen peroxide stage, the so-called ‘White Rose’ project, started up in 2007. In January 2008, the peroxide pulp bleaching technology was launched. The Twister was installed into the post-cleaning stage before the pulp drying machine, which has a capacity of 450 tonnes a day. When the hydrocyclone cleaning process is used conventionally before the drying machine, the pulp is run at fairly low consistencies. The pulp’s consistency is then raised afterwards to 1.5-2.0 per cent before it enters the drying machine. The Twister simplifies the cleaning process because the pulp is run through the Twister at higher consistencies and then run directly to the paper machine. As a part of the ‘White Rose’ project GL&V’s Celleco Twister hydrocyclone system was installed before the pulp drying machine. Peter Baláž, Technology and Pulp Quality MONDI SCP’S MILL AT RUžOMBEROK: ON THE ROAD TO QUALITY IMPROVEMENTS Manager at Pulp Division and Dušan Spratek, Pulp Division Specialist, were responsible for the Twister operations at Mondi SCP. Baláž explained how CellecoTwister become part of the Mondi SCP`s ‘White Rose’ process. “In 2007 we slightly increased production and our drying machine became more and more important because we are a fully integrated pulp• GL&V PAPER MAKING & DISTRIBUTION mill. We produce pulp for our paper machines but part of the production is sold as market pulp,” he says. “So when this volume began to get bigger and bigger we decided to invest in improving the quality of the dry pulp. That was the reason we were looking for a partner to improve the cleaning systems.” Another reason for the change was because no separate specialised cleaning system was being used at Mondi SCP “Our drying machine did not have a cleaning system because the cleaning system was integrated directly into the pulp mill,” says Baláž. “We have both an unbleached cleaning system and a bleached cleaning system at the pulp mill. “On the unbleached side there are pressure screens and a slotted screen and on the bleached side a combination of the two.” That was when Mondi turned to the Celleco Twister as a post-cleaning system. “We were looking for a reasonably priced option, and GL&V offered us a very efficient system,” says Baláž. “It was the system efficiency and the price which were very important for us. Twister could run at very high consistency DUšAN SPRATEK, PULP DIVISION SPECIALIST, AT MONDI SCP WITH PETER BALÁž, TECHNOLOGY AND PULP QUALITY MANAGER AT PULP DIVISION. • regarding the cleaners – guaranteed figures were 1.4-1.6 per cent in the stream that goes to the drying machine´s headbox. This was one of the main factors when we decided to put our trust in GL&V.” But it wasn’t just the level of consistency that provide the appeal for the system; there were additional benefits. “Before this investment, we had no trouble in keeping up the consistency,” said Baláž. “From the consistency point of view the benefit is the volume of the scope. You can run it at high consistencies and you do not need large-volume slurry pumps. Regarding the headbox consistency, we are on the same level as before.” Baláž explains that the installation of the Twister provided energy savings only in the drying process.“In our case we are on the same [energy] level as we were before. We were not replacing anything but expanding the process. The quality of the pulp is better now and that is the main point.” Since the line started production in 1981 only minor modifications have been made, says Baláž. “We are an integrated pulp mill and we produce copy papers so most of the production is going into the paper machine,” he says. “Only the excess pulp production is going into the dryer. From that point of view the drying machine is not fully utilised.” Connecting the drying machine to the fibre line was the project called ‘White Rose’, says Baláž. “‘White’ as in the brightness of the pulp, because it was connected to an additional PO stage at the end of the fibre line. The aim was to get higher capacity for bleaching. So that was where ‘White’ comes from while ‘Rose’ was connected with the name of our city. Ružomberok actually means ‘the town of roses’. “When we were running the fibre line at full capacity we were not able to reach the final brightness, so that was the reason we added a PO stage to the end of the fibre line. The start-up was in January 2008 and that project was connected to the screening of the drying machine.” Baláž says that the mill is running “very nicely” now. “We are increasing production step by step. The big change was implemented by the investments in 2003- 2004 and now we finished the ‘White Rose’ project. So we are really increasing pulp production. Now we are producing about 460,000 t/a of air-dry bleached pulp. “We are looking for possibilities to minimise chemical costs and we have been able to replace some chlorine dioxide with hydrogen peroxide by adding an extra stage to find out the optimum amounts. The earlier investment taught us a lot. Start of the Twister was at the end of last year, after which a number of tests were carried out. “First was the G1 test on the system’s runnability, which was okay,” says Baláž. “Then we entered the G2 stage where we ran the system for a certain time to see if it would meet the targets. That was okay as well. The final stage was to test the purities level, consistency, fibre losses – all of them were just fine.” The result was higher purity levels, says Baláž. “The better the pulp quality, the better price we get for it. We sell some 50,000 tons of market pulp a year.” More information from Markku Pitkänen, managing director, GL&V Finland Oy, PO Box 161, Sinikalliontie 9, FIN-02631 Espoo, Finland. Tel.: 358 9 5766 5600. Fax: 358 9 5766 5656. E-mail: markku.pitkanen@glv.com Web: www.glv.com Celleco Twister: what is it? The Celleco Twister is claimed to be a radical new concept in hydrocyclone technology. It houses three forward cleaners in a single unit, each of which is equipped with the patented two-stage cone working together with the patented Mid-cone Dilution technology. The Mid-cone Dilution technology re-energizes the stock while providing accurate dilution minimizing fibre thickening. It enables the hydrocyclone to have an elongated cone section for higher separation efficiencies without the need to operate the hydrocyclones at an elevated pressure drop. The Celleco Twister cone and Mid-cone Dilution technologies enable an energy reduction up to 50 per cent compared to conventional cleaners at the same pressure drop and is based on the fact that it can operate at feed consistencies of up to 2 per cent. What is GL&V Pulp and Paper? GL&V Pulp and Paper, a division of Canada-based company GLV Inc, is a global enterprise in technology and processes for manufacturing of pulp and paper as well as in production and treatment of fresh, process and waste waters. It is one of the largest suppliers of pulp and paper production equipment and a world leader in equipment rebuilds, uppgrades and optimisation. E fficient dewatering is the main purpose of a paper machine’s press section. Voith Paper has improved this process by developing two new suction roll covers. Using advanced bonding systems, these new covers can simultaneously achieve the highest levels of dryness and save energy. Voith Paper continues to examine the potential of the dewatering process at its Paper Technology Center, employing combinations of roll covers and felts, as well as through operational testing. For many years, the aerospace and automotive industries have used a special bonding process, known as the Interpenetrated Network (IPN), to connect different types of polymers. Today, Voith Paper is using a similar process in its WebNet technology to create the newest generation of suction roll covers: AquaFlow and SolarFlow, which offer tangible advantages. Thanks to the three dimensional interlinking of individual polymers, the interface between these new covers and the roll shell is even stronger. As a result, these new covers are also much more resilient, offering higher resistance to temperature changes as well as chemical and mechanical stress. Due to these improved characteristics, WebNet technology will replace the already successful AST-bonding layer which was developed in the 1990s. WebNet technology plays a key role in the construction of the roll covers. Surrounding the roll’s metal shell and interface is a fiber-reinforced multi-layer base with marginally thicker construction and higher structural elasticity. Here, WebNet technology links the roll’s multi layer base with the cover’s polyurethane top stock, which Voith Paper also improved for both its AquaFlow and SolarFlow covers. Thanks to these covers’ high- LIFECYCLES OF AQUAFLOW AND SOLARFLOW COVERS ARE LONGER THAN CONVENTIONAL ROLL COVERS density molecular structure, their elasticity, mechanical stability, abrasion resistance, as well as their hydrolytic characteristics, have been significantly improved. Recently, the advantages of these new polyurethane covers were clearly demonstrated at the Leinfelder Paper Mill in Schwedt, Germany, where linerboard is produced. Says Arno Liendl, Technical Director at Leinfelder Schwedt: “Our tests using the SolarFlow and the SolarPress roll covers were a complete success. In the press section of PM 3, the dewatering process was improved by 1 percent.” Additionally, in combination with other improvements, the production speed and output were increased. Michael Weinzettl, Voith Paper’s Product Manager for polyurethane rolls, explains the differences between Aquaflow and Solarflow: “AquaFlow covers use the new polyurethane top stock layer, while SolarFlow covers use further enhanced materials.” SolarFlow covers have a higher surface stability, which assures optimum impounding volumes during operations and under high loads. That’s also why premium SolarFlow covers are ideally suited for extremely strained suction rolls. Voith Paper’s experts can precisely tailor a cover’s surface characteristics to satisfy its individual installation and operating requirements. “Plus, by using our NipMaster computer simulation we can establish a dewatering profile that also involves various press felt parameters,” adds Weinzettl. Because if the structure of the polyurethane layer, these new covers can have even deeper grooves for more effective dewatering. Specifically, AquaFlow covers have groove depths of up to 2.3mm and widths from 0.5 to 0.9mm, with partitioning between the grooves of 2.0 to 2.5mm. And in the case of MAIN PICTURE: WEBNET TECHNOLOGY PLAYS A KEY ROLE IN THE CONSTRUCTION OF THE ROLL COVERS dewatering SolarFlow covers these dimensions are even more impressive, having groove depths of up to 3.0mm and widths from 0.4 to 0.9mm, with partitioning between the grooves of 1.8 to 2.5mm. In both cases, the deeper grooves used by these covers significantly increase their water storage volume, as well as the speed and efficiency of the dewatering process. These same characteristics also ensure efficient nip­dewatering and lower hydraulic pressure in the nip itself. As a result, blind holes in the cover’s surface, which have a low operating volume due to insufficient drainage, are no longer needed. Thus uhle boxes for felt conditioning can be omitted – which saves energy. Furthermore, blind holes often cause shadow marking. In fact, during a test of SolarFlow on a paper machine producing copy paper, shadow marking was completely eliminated and the dryness was increased from 0.7 to 1.0 percent. The lifecycles of AquaFlow and SolarFlow covers are far longer than conventional roll covers. This is primarily due to their use of high-quality polyurethane, whose higher abrasion resistance results in far longer replacement intervals – with uniform dewatering characteristics in the nip throughout the cover’s lifecycle. When the new covers were tested on a paper machine producing testliner and corrugated paper, the replacement interval was twice as long as conventional covers and, at the same time, nip-dewatering increased. The Scheufelen Paper Mill in Lenningen, Germany, which produces wood-free coated premium paper, has seen similar results. Here, the new roll covers had a particularly positive effect on the press felts: the lifecycle of the pick-up felts increased from 21 to 32 days, while the felt’s break-in periods decreased. “We were very impressed with the SolarFlow’s performance and we achieved our production targets in a surprising short period of time,” said Ralf Haury, Production Manager at Scheufelen. At another paper mill, the effect of high-quality roll covers on the press felts was even more dramatic: increasing the felts’ lifecycle from 14 to 45 days. “We see the greatest improvement potential in using the right combination of roll covers, felts, and doctor blades,” said Peter Mödl, Product Manager for press felts at Voith Paper. Maximum dewatering can only be achieved when all three of these components work effectively together. “Because even if roll covers are ingenious, when they’re not compatible with the felts their benefits can’t be exploited,” added Mödl. With its new E-Flex press felts, Voith Paper offers paper manufacturers another advanced solution. E-Flex felts also have an optimised structure and use polymer interlinking on their inner surface for optimum ‘bridging’ of the grooves in a roll cover. This ensures uniform pressure distribution across the entire felt surface. In addition, the elasticity of the E-Flex felt improves its resilience and ensures more efficient dewatering characteristics throughout its lifecycle. While operating on the paper machine, E-Flex promotes more water flow to the suction roll cover due to the felt structure having marginal flow resistance. At Voith’s Paper Technology Center in Heidenheim, Germany, various combinations of roll covers and felt designs have been tested on the VPM 6 experimental paper machine. These tests have shown that the greatest improvements in the dewatering process can be achieved when the covers and felts are appropriately paired. Voith Paper’s tests have also shown that in actual operation, the advantages of varying groove depths on AquaFlow and SolarFlow covers can be fully utilized when combined with E-Flex felts. In conclusion, the best results were achieved when the doctor blades were also adapted to suit the roll cover’s operating characteristics. * Andreas Weis is Senior Product Manager, Press Section, Voith Paper Fabrics Düren GmbH. People PAPER MAKING & DISTRIBUTION Winner of the Huyck.Wangner talent award in its tenth year was Florian Schmid, a 27-year-old from Germany’s Allgäu region who graduated at the top of his class. The award – worth 1,500 euros – is made by the paper machine clothing manufacturer in cooperation with the Munich University of Applied Sciences' faculty of Process Engineering Ernst Kerschhofer, Director PMC Sales & Marketing Huyck.Wangner, and Prof. Stephan Kleemann, PhD, head of the Process Engineering - Paper and Packaging course at the Munich University of Applied Sciences, presented the award during the closing ceremony in July. Florian Schmid chose a papermaking career by chance. During his career counseling, he liked what he saw about the interesting environment associated with the paper industry and enrolled as a papermaking apprentice. He completed his apprenticeship close to home at Hans Kolb Wellpappe in Kaufbeuren and gathered further experience at Mondi Packaging Raubling. After that, he hit the books again at the advanced vocational school in Kaufbeuren, from which he received an advanced technical college certificate. “I wanted to improve my opportunities by continuing my educa­tion and establishing a broad basis for a career in the paper indus­try,” said Schmid. “That is why I decided to study at the University of Munich and also obtain an insight into other paper industry sec­tors, beyond corrugated board base paper.” In his spare time, he is an avid snowboarder, wakeboarder and mountain biker. Florian Schmid wins Huyck.Wangner talent award British tour for Arctic Paper’s Soale Arctic Paper’s UK Business Development Manager, Mark Soale has embarked on a national tour of merchant stockist PaperCo’s sales offices to deliver the Amber product brand awareness cam­paign and demonstrate the excellent qualities of the range. The campaign will provide brand awareness and product infor­mation for the PaperCo’s sales team. A series of fact cards have been produced to help illustrate the qualities of the Amber prod­uct range, and raise awareness of the outstanding environmental aspects of the Amber Graphic and Preprint product ranges. The fact cards are available for the PaperCo sales offices to coin­cide with a new product mailer that has been produced for Amber, all of which will provide useful sales tools for PaperCo personnel. Soale has created a series of quizzes for the sales offices with questions about the Amber product range and other related sub­jects to help provide useful and informative sales information for the PaperCo sales team in a lighthearted way. A number of promotional items such as pens, business card holders and mints will also be handed out to promote the Amber brand name. And what better way to help them enjoy the whole campaign process than with their own Amber Cake and Amber tea mugs, which Mark is taking into the offices to provide much needed refreshment, and even making the tea for them. Dr Anne Brunila, who has been president and chief executive of the Finnish Forest Industries Federation (FFIF) since 2006, has accepted a position in the management of another organization. “Under the management of Dr Brunila, the Finnish Forest Industries Federation has developed its effectiveness as active branch organization and the Federation has an important role in promoting the success of the Finnish forest industries,” said Kari Jordan, chairman of FFIF and president and chief executive of the Metsäliitto Group. “The Federation’s work will be continued on the basis of its strong expertise while the Board is looking for a successor to continue the work for the Finnish forest industries,” said Jordan. • Jari Forss (pictured left) was appointed executive vice president and deputy to the chief executive of the FIFF in September. He has been working as head of Federation’s labour market unit since 2006, and will also continue in this position. FIFF chief executive moves on FROMLEFTTORIGHT: PROFESSOR STEPHAN KLEEMANN, PHD, HEAD OF THE PROCESS ENGINEERING - PAPER AND PACKAGING COURSE WITH TALENT AWARD WINNER FLORIAN SCHMID AND ERNST KERSCHHOFER, DIRECTOR PMC SALES & MARKETING HUYCK.WANGNER Real-time turbine blade tip condition monitoring A digital signal processing unit (DSP) for the real-time monitoring of turbine blade conditions has been launched by Monitran Technology, the R&D arm of vibration and displacement sensor OEM Monitran. The unit reflects ‘live’ blade health by providing traffic-light­type indicators: green for safe, amber for advisory and red for danger. Also, for each condition, there is a programmable output capable of switching up to 30V at 5A, which means the unit can be easily integrated into control circuitry and to provide an automatic shut-down of the turbine if necessary. Donald Lyon, Monitran Technology’s managing director, said: “Up until now, turbine blade health monitoring has required the capture of data, often with the turbine off­line, and then extensive and time-consuming data analysis. “Our DSP unit affords real-time, in-situ data analysis, allowing plant owners and other users of turbines to adopt predictive maintenance strategies, and to operate more cost-effectively. Also, if the unit is playing a role in the turbine’s control circuitry, it can reduce the risk of catastrophic failure if something does go wrong.” The DSP unit has four channels which are each intended for use with an eddy-current probe and suitable trigger circuitry (such as Monitran’s T3 unit) and processes data relating to blade-tip-to-casing clearance and by recognising any blade-to-blade lead or lag issues. The use of all four channels supports the placement of sensors at approximately 90 degree intervals around the turbine’s casing. Lyon adds: “Investigatory work we conducted with QinetiQ indicated that blade deterioration can occur in less than a single revolution.” A fifth channel on the unit is intended for a traditional accelerometer, so that vibration levels may also contribute to the overall picture of turbine health. In addition, all five channels feature digital buffers for pre- and post-trigger recording, and can feed external digital recorders. The unit is in a standard DIN rail mount format, and measure 156 x 86 x 56mm (L, D and H respectively). More information from www.monitrantechnology.com Pulp & paper flowmetering expertise shared Guides that provide tips on flowmeter selection for pulp and paper applications have been published by ABB. ‘The Instant Guide to flow measure­ment in pulp and paper applications’ compares the benefits of DC and AC electro­magnetic flow meters for pulp and paper production lines and explains which type of flow meter is best suited to spe­cific tasks. Available in pdf format, the guide provides a comprehensive explanation of the technologies available, including a comparison of their respective advantages. Also included are hyperlinks to further publications providing relevant useful information. The second publication ensures consistent production performance for Caledonian Paper. ABB AC-Master is a factfile based on an application at the UPM Caledonian Paper plant in Ayshire. It explains how installing an AC flow meter helped overcome production problems, resulting in greatly enhanced measurement accuracy. Traditionally, AC excitation magmeters have tended to hold a dominant position over their ‘pulsed DC’ excitation counterparts due to their ability to deliver more accurate measurement in the noisy conditions inherent in paper production applications. However, recent technological advances have helped to overcome these problems, opening up new avenues for the use of pulsed DC magmeters in pulp and paper applications and providing a lower cost alternative to AC magmeters in certain applications. ABB’s new ProcessMaster pulsed DC flow meter, for example, now offers an increased excitation frequency which runs up to four times as fast as its previous DC-powered models. Modern magnetic materials and the inclusion of new fast noise reduction algorithms and Digital Signal Processing (DSP) technology enable a fast flow response even in noisy applications. To obtain the guides email your name and company to moreinstrumentation@gb.abb.c om. For more information visit www.abb.com/instrumentation