The customer magazine of Andritz Pulp & Paper Issue 2 — 2005

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SONOCO Sonoco, founded in 1899 as the Southern Novelty Company in the USA, operates in 32 countries, producing packaging for a variety of industries and for many of the most recognized global brands. With its 18,000 employees today, it is the world's largest producer of engineered carriers made of fiber, plastic, and composite materials. Sonoco processes more than one million tonnes of recycled paper annually. In 1992, Sonoco purchased the Trent Valley Mill from Paperboard Industries Corp. Trent Valley (near Trenton, Ontario, Canada) has been in operation since 1880 at the same site near the Trent Canal (386 km waterway linking the Bay of Quinte of Lake Ontario with the Georgian Bay of Lake Huron). The mill manufactures coreboard, canboard, and linerboard products from 100% recycled paper. All of the mill's products are produced on a Kobayashi Ultraformer, 177-inch trim at a speed of 630 fpm, purchased in 1977. The machine can produce about 300 t/d of up to six-ply board. In addition to base-stock, the mill has capabilities to slit its products on-site down to 2-1/8 inch widths. 26 FiberSpectrum Issue 2 — 2005 High quality, lower costs With improved refining, Trent Valley has been able to shift its attention to optimization projects. "We're working on lowering basis weight and doing all kinds of fun stuff with the kraft portion of the sheet," exclaims Giffen. "The linerboard we produced was 83% OCC in five plies and 17% kraft in one ply," says Giffen. "However, the kraft constituted over 65% of the furnish cost. The kraft made the sheet look equivalent to what could be produced from virgin kraft. It is sold as a premium sheet. With the LemaxX Spiral TM , we've been able to cut the amount of kraft dramatically. We've made big improvements in our cost structure without having to worry about the final quality of the sheet." Kyle Gaetano, Paper Mill Superintendent, on the Kobayashi Ultraformer machine. The machine can produce about 300 t/d of up to six-ply board. "We're also pleased with the life we get out of the plates," Giffen says. "And, now that we have been running them for seven months, we're seeing consistently lower energy for the same output. It's about 80 horsepower per day. Not a huge number, but it definitely pays for the plates." Facing constant variations in incoming wastepaper, Sonoco views the LemaxX Spiral TM plate as a tool that "helps us take some of those fluctuations out."
August Koehler AG (Germany): Energy savings and durability As Andritz developed the LemaxX Spiral TM , it needed a willing customer to test and further develop the concept. It found a partner in a mill owned by August Koehler AG, located in the Baden region of Germany. The people at Koehler are very open to new technology. Koehler was established in 1807. It is one of the few remaining independent papermakers in Germany, leading the world market in thermal papers and is also among the leading suppliers of carbonless papers. Paper production is about 430,000 t/a spread over five mills. Testing the Spiral at Kehl The Kehl mill is the most modern in the August Koehler Group. The mill operates three modern paper machines. Two of the machines have set world records for their grades (thermal paper and décor paper). Joachim Fuchs, Production Foreman, in front of one PM2's refiners with the LemaxX Spiral TM plates installed. The refiners on PM1 and PM2 have been using LemaxX Spiral TM refiner plates since 2004. Robert Lamm and Joachim Fuchs, Production Foremen for PM1 and PM2, and Georg Streif and Clemens Fahrenwald, Production Managers, have worked closely with Andritz and the LemaxX Spiral TM . Low energy consumption was what first appealed to Fuchs. "We were willing to try something new, as that is the only way to improve," Fuchs says. Koehler's fiber mix is roughly 70% eucalyptus and 30% softwood. More than 5000 l/min flow through the refiners at a consistency about 5%. Two of the four refiners in the PM2 line have been fitted with LemaxX Spiral TM refiner plates, and 140-225 less kW are consumed in the line per hour. Fuchs’ calculations show an annual savings of 75,000 EUR simply by replacing two refiner plates. "Of course, the initial cost of the LemaxX Spiral TM is a little higher and the service life is somewhat shorter," says Fuchs. "We still calculate a savings of about 40,000 to 50,000 euro a year." The new plates increase the fiber breaking length by more than 10%. The higher strength means that the mill no longer has to add dry strength polymers and there are fewer breaks on the PM2, which increases production efficiency considerably. A "foreign" matter at PM1 PM1 was more of a challenge for the spiral plates. There is no junk trap to remove foreign materials before they reach the refiners. Anything from a paper clip to an entire bolt enter the refiners, and sometimes can have disastrous results. Robert Lamm, Production Foreman for PM1 at the Kehl mill. Once, foreign material caused an explosion in the refiner — sending pieces of refiner lining and broken plates into the stock preparation system. The entire paper machine came to a standstill. "All we could do was open everything up and clean it out," remembers Lamm. Fuchs told Lamm about the new refiner plates from Andritz that were working so well on PM2. "I thought maybe they could handle the debris in the stock better than what we were using, so I phoned Markus Purgstaller of Andritz," Lamm says. Purgstaller supervised installation of LemaxX Spiral TM plates for the five refiners ahead of PM1. "The spiral plate does not break," Lamm says. "Foreign matter either gets stuck or it goes through the refiner, but there is no more wreckage that ruins the entire line. The extreme case has been a bolt from somewhere entering the refiner. What previously would have paralyzed the paper machine now left only a single trace — bent refining bars." The LemaxX Spiral TM also improved refining results and saved energy on the PM1 line. "We refine at 35° SR at the same energy input as we previously needed for 30° SR," Lamm says. Now that the new plates have been installed, Lamm no longer needs to run the fifth refiner, so he can keep it as a standby unit, or for additional capacity when needed. Find out more at www.fiberspectrum.andritz.com Issue 2 — 2005 FiberSpectrum 27
Page 1 and 2: The customer magazine of Andritz Pu
Page 3 and 4: Low-tech? No way. The average perso
Page 5 and 6: "In an EPC delivery, Andritz is muc
Page 7 and 8: The Andritz Twin Wire Pulp Machine
Page 9 and 10: Andritz delivered the recausticizin
Page 11 and 12: Part of the Ash Re-Crystallization
Page 13 and 14: The FibreFlow ® drum at Cartiere d
Page 15 and 16: Scantamburlo explains: "The quality
Page 17 and 18: as engineering for the stock prepar
Page 19 and 20: High quality fiber from low quality
Page 21 and 22: Andritz woodyard Jiangxi Chenming u
Page 23 and 24: ening/dewatering with Disc Filters
Page 25: Ring crush is a critical quality te

The customer magazine of Andritz Pulp & Paper Issue 2 — 2005

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