2005

Erwin Holzinger

Paper Machines Board and Packagingerwin.holzinger@voith.com

On February 12, 2005, paper machine No. 1 started up

at the new Adolf Jass Schwarza mill in Rudolstadt/Thüringen,

Germany. It set a new world record for packaging board machines

straightaway, with a start-up speed of 1,105 m/min at 100 g/m2

basis weight. This new greenfield mill will produce up to

400,000 t.p.a. of corrugating medium and testliner at 75-125 g/m2

basis weight, using 100 % recovered paper.

Adolf Jass, Schwarza –World record for packaging paper machines

which helped to ensure a successfulstart-up in all sections.

The MultiForm A forming fabric qualitiesproved themselves, with a very stablestart-up behaviour and dependable re-sponse. These innovative high-tech form-ing fabrics, a state-of-the-art Voith PaperFabrics development, help toward the on-going optimization of high speed papermachines and modern cleaning systems.

Complete PM 1 line delivered by Voith Paper

Voith Paper delivered the entire processtechnology for this new production line –from stock preparation to winder includ-ing automation components – based onthe One Platform Concept. The Voithscope of supply also included the initialstart-up clothing according to the VoithPaper Fabrics Multi Platform concept,

Roland Rauch

Fiber Systemsroland.rauch@voith.com

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2005

Fig. 1: TwinDrum pulping system, with pulperdrum on the left and screen drum on the right.

Fig. 2: 3-stage EcoMizer cleaner system.

Fig. 3: The Adolf Jass Schwarza paper mill inRudolstadt/Thüringen.

Focus on customer benefit

Already at the planning stage, this newinstallation took account of the latestpackaging machine experiences from wellknown reference installations. Both thecustomer and Voith paid great attentionto using well-proven technology. The en-tire packaging paper machine is the firstone ever to be designed in “industrialdesign” throughout.

Stock preparation

The stock preparation system is designedfor a total capacity of 1,300 t/24 h fin-ished stock based on 100% recoveredpaper. Voith supplied the entire stockpreparation equipment, from bale de-wiring and charging, pulping and highconsistency cleaning, hole screening,fractionation, long and short fiber clean-ing, long fiber screening as well as thick-ening, through to process water and re-jects handling technology.

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Recovered paper is fed into the stockpreparation system via a bale dewirer andcharging system with a capacity ofaround 120 bales per hour, supplied byVoith Paper Euskirchen. The dewiredbales are fed to the main highlight of thestock preparation system, the TwinDrumpulping system (Fig. 1). This TwinDrumpulper at Jass Schwarza has the largestcapacity among TwinDrums installed sofar. The raw material is then passed viahigh consistency cleaning to a 3-stagepre-screening system (MSM MultiSorterand Combisorter with cleaner) for effec-tive pre-screening.

After pre-screening, the stock is fraction-ated into short and long fiber fractions inan MSF MultiFractor. The long and shortfiber components are subsequentlycleaned in 3-stage EcoMizer cleaner sys-tems (Fig. 2). The long fiber fraction is

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additionally screened in a 3-stage slotscreening arrangement. Both fiber com-ponents are then thickened in Voith Bag-less disc filters.

Voith’s joint-venture partner meri sup-plied the entire rejects handling equip-ment, including metal detection andmagnetic separation, coarse and fineshredding and compactors. For effluenttreatment meri’s proven Deltapurge andElephant machines have been selected.Sludge pre-thickening is via a Bluedraingravity table. A high efficiency sludgescrew press (Fig. 5), – an entirely newproduct development from Voith – is in-stalled directly after Bluedrain.

This clearly defined stock preparationconcept has enabled the mill to success-fully reach its goals of gentle pulping and

ity, they also provide optimum screening-out characteristics. There are no fiberlosses in the approach flow, since thescreen rejects are fed back to stockpreparation. This patented Voith processsets new standards in efficiency andeconomy.

Four CP CompactPulpers handle the pa-per machine broke which is then returnedto the stock preparation system. This en-sures the paper machine is always fedwith optimally prepared stock. Any conta-minants in the broke are thus removedbefore they can interfere with paper ma-chine runnability or product quality.

The scope of stock preparation supplyalso included water management and en-gineering consultant services for the en-gineering partner appointed by Jass, as

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earliest possible contaminant removalfrom the stock suspension.

Approach flow, whitewatercircuit and broke handling

The Advanced Wet End Process has beenfully implemented here. Voith’s provenComMix and HydroMix mixing compo-nents have been installed in the approachflow with the result that an improvementin web profile stability has been con-firmed. VoithVac full-flow deaeration isinstalled for both the top- and backliner(Fig. 6).

Directly ahead of the headbox, Multi-Screen MSA screens are in operation forboth the top- and for the backliner. Thesenot only ensure excellent hydraulic stabil-

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2005

Technical data

Machine PM 1

Untrimmed width 7,600 mm

Design speed 1,500 m/min

Grade Corrugating medium and testliner

Basis weight 75 -125 g/m2

Production capacity (gross) 1,300 t / 24 h

Fig. 4: PM 1 with DuoFormer Base andMasterJet M2.

Fig. 5: Voith’s new sludge screw press installeddirectly after meri’s Bluedrain.

Fig. 6: The two VoithVac deaeration units for thetop- and backliner.

Fig. 7: SpeedSizer.

Fig. 8: Voith Fabrics MultiForm A quality pressfelt.

well as complete erection, commission-ing and basic optimization of the stockpreparation system and wet end processcomponents.

Paper machine

Sheet formation takes place in a Duo-Former Base specially designed for high-speed packaging paper production. Thedrainage section, comprising a vacuum-augmented forming roll followed by acurved top wire suction box, ensuresexcellent formation with good retentionvalues.

The MasterJet M2 headbox is fitted withthe well-proven OnQ ModuleJet dilutionwater control system. This two-layerheadbox guarantees the best possible uti-

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lization of strength potential, while at thesame time ensuring optimal economicalfurnish use. In the headbox nozzle thetwo layers are separated by a stiff lamel-la, thus allowing different jet-wirespeeds. Basis weight CD-profile controlis by a Profilmatic dilution water controlon the back layer. Thanks to the uniform-ly controlled basis weight profile, optimalpaper quality is attained at an early stagein the production process. Both tools arevery valuable for strength optimization.

In the press section, a DuoCentri-Nipco-Flex press with a shoe press in the thirdnip ensures optimal runnability. Highquality roll covers are used here, such asthe MagnaPress II, Aqualis and Cera-Lease SDe. After the press, optimal dry-ness and moisture profile are guaranteedby the zone-controlled OnQ ModuleSteam

blow box on the double suction press rollwith Profilmatic control software. Localdrainage is improved by the OnQ Mod-uleSteam unit, which also eliminates anymoisture streaks in the web CD-profilebefore reaching the dryer section. TheMultiFlex O3 felt for pickup and first nip,MultiFlex D2 as bottom felt and MultiFlexV3 for the third press are the optimal se-lection for the DuoCentri-NipcoFlex press.Right from start-up, the results were ex-cellent drainage efficiency with high wearresistance.

The entire pre-dryer section is designedaccording to the TopDuoRun concept,comprising six single-tier dryer groupswith 31 drying cylinders in total. Pro-Release boxes in the first two dryergroups ensure excellent runnability at lowbasis weights and highest operating

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2005

When did you first think about building anew plant here in Rudolstadt? And whatwere the reasons?

Jass-Teichmann: Just after the turn ofthe millennium we started thinking aboutexpanding our company by building anew paper mill. Then as now and in theforeseeable future, we have to meet thesteep growth in market demand for light-weight testliner and corrugating medium.We chose Rudolstadt/Schwarza as a loca-tion for various reasons.

First, we have an outstandingly good in-frastructure here. The site is next to theriver Saale. Not far away are a power sta-tion and an industrial effluent treatmentplant, and soon there will also be an in-cineration plant. Furthermore, we alsohave an on-site rail connection. Second,Rudolstadt is centrally situated in Ger-many and Europe – like our parent mill inFulda. It is excellent positioned logistical-ly with regard to the rapidly growing EastEuropean markets. And with Fulda onlyabout 170 km away, we can specializeeach of our three paper machines forspecific basis weight ranges. This en-ables us to serve our customers withoptimal paper quality as well as fast andreliable deliveries. That would not bepossible if we had built our new mill along way away to serve a single regionalmarket.

Why did you place this order with Voith Paper?

Prinzhorn: We have a long and reliablepartnership with Voith. Back in thenineties Voith handled the complete re-build and expansion of both our papermachines in Fulda. The great success ofthose projects alone proved Voith’s out-standing competence. Another reason forplacing the Schwarza PM 1 order wasVoith’s already well-proven know-how onhigh speed paper machine technology forlightweight corrugating medium and test-liner.

What is your opinion of Voith’s projecthandling and cooperation?

Jass-Teichmann: For good reasons, wedecided to place the order on an all-inclu-sive basis. Voith’s scope of supply cov-ered the entire production line, from re-covered paper bale handling and dewiringon one end, to the winder on the otherend. By minimizing the number of inter-faces involved, this certainly speeded upthe project, so that we had paper on reelonly 14 months after starting construc-tion work.

Voith’s outstanding dependability ismatched by its unsurpassed technicalcompetence. Another important point forus is the Voith support after the commis-

sioning, so that together, we can opti-mize this machine for maximum perfor-mance.

What has been your experience since thestart-up on February 12, 2005?

Jass-Teichmann: In the night of thestart-up we made a toast of a steep start-up curve – and it is indeed steep. Onlyeight months after commissioning, weregularly run the machine at speeds of1,250 to 1,300 m/min. And the design ca-pacity of 1,300 t per day has already beenexceeded several times: our newestrecord is 1,463 t. In other words, we arepleased to say that everything is proceed-ing very satisfactorily.

Your PM 1 is one of the world’s mostmodern and fastest packaging papermachines. Is the latest paper machinetechnology a must for your productquality?

Prinzhorn: As mentioned, we use ourPM 1 to meet the new and growing mar-ket demand for lightweight packaginggrades. With these basis weights of 70 -100 g/m2 for corrugating medium and90 - 120 g/m2 for testliner, appropriatenew technology concepts were indispens-able to meet product requirements forcross-profile stiffness (SCT) and highest

On the occasion of the new Rudolstadt/Schwarza mill inauguration on

September 22, 2005 we took the opportunity to interview Dr Marietta Jass-Teichmann,

Managing Director, and Holger Prinzhorn, CEO Adolf Jass:

Dr MariettaJass-Teichmann

ManagingDirectorPapierfabrikAdolf Jass

HolgerPrinzhorn

CEOPapierfabrikAdolf Jass

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2005

speeds. They provide a controlled webtransfer from drying cylinder to dryerfabric thanks to a special high-vacuumzone. The after-dryer section is a combi-nation of a TopDuoRun with four single-tier dryer groups combined with one dou-ble-tier CombiDuoRun dryer group.Thanks to the separate heating of top andbottom drying cylinder, perfect sheet flat-ness can be attained. Five DuoCleanerExpress units are installed for efficientdryer fabric cleaning.

Uniform and faultless starch applicationis ensured by a Speedsizer with state-of-the-art Voith roll covers. Large diameterrods are used here for the first time. Car-bon fiber blade beams enable starch ap-plication at very high temperatures. AVoith Krieger Airturn ensures optimalcontactless web transfer from the Speed-sizer to the after-dryer section. The entiredryer section is equipped with a ropelesstail transfer system, while Fibron transferequipment is used in the Speedsizer andSirius reel areas.

Paper coming from the after-dryer sec-tion is wound up on a Sirius reel,equipped with center drive and integratedRollMaster hardness control – to a maxi-mum diameter of 4,400 mm. The reelturn up is carried out with a EcoChangeW automatically – the web is cut with ahigh-pressure water jet.

The OnV machine monitoring systemcovers the pulper drives, the approachflow section and the entire paper ma-chine. By giving early warning of immi-nent bearing failure, the monitoring sys-tem improves the runnability of PM 1 asa whole. OnV machine monitoring is alsoa valuable tool for optimizing mainte-nance shutdown planning.

Winder

A single VariFlex L two-drum winder han-dles the entire output thanks to its highperformance – in particular featuring ahigh degree of automation, operatingspeeds up to 2,800 m/min, high accelera-tion and deceleration rates, flying spliceat the unwind, and extremely fast set-change times.

Successful commissioning

The successful commissioning of this en-tire production line – well before theagreed deadline – is thanks to the out-standing teamwork distinguishing thislarge project. Congratulations are due toall concerned, particularly to the JassSchwarza team for its highly professionaland efficient project leadership.

Fig. 9: VariFlex L two-drum winder.

possible homogeneity. Lightweight paperproduction also demands much highermachine speeds to ensure the high out-puts required for cost-effectiveness asagainst conventional production lines.Furthermore, the entire technologicalconcept of the stock preparation line andpaper machine must reduce the otherwisegreater sheet brake risk at low basisweights.

You are one of the largest producers ofcorrugating medium in Germany. Whatdoes the future hold for Jass? What areyour goals?

Jass-Teichmann: We think SchwarzaPM 1 will be operated at design capacityby 2007 at the latest. In other words, to-gether with our two paper machines inFulda we shall be producing around900,000 t.p.a. of corrugating medium lin-er by then. Our market share in Germanywill then be about 20 %. Our goals for thefuture are to go on creating a market ad-vantage for our customers with absolute-ly first-class product quality and reliabledeliveries. And for our employees to en-joy working in a family-owned enterpriseon state-of-the-art technology.

Many thanks indeed for this interview –and congratulations on your new produc-tion line!