A narrow time window, a size press operating at its maximum speed and the need for greater machine efficiency were the various challenges faced by the Voith team as it tackled the upgrade of PM 6 at Smurfit Kappa. Thanks to excellent planning beforehand, the machine was restarted without problems one day ahead of schedule. “The startup of the new SpeedSizer has shown how expertise and dedication bring about an excellent outcome. The project simply flew by,” says Jochem Meier, Manager Operations at Smurfit Kappa in Zülpich.
Smurfit Kappa wanted to achieve a higher production speed through its modernization of the PM 6 at its Zülpich mill that produces testliner and recycled fluting in basis weights of 100 to 150 grams per square meter from 100 percent recovered paper. A key aspect of the project was the puddle-type size press. Equipped with a deflection compensation roll, it allowed an optimum CD profile of the nip load (linear contact pressure) and for a long time had guaranteed the high quality of the paper. But for technical reasons, the size press limited the production speed of PM 6 to 1,150 meters per minute. Even though the size press was one of the fastest in the world, it prevented the machine from being ramped up to the 1,225 meters per minute desired by the customer.
Voith recommended installing a customized SpeedSizer AT with the existing Nipco deflection compensating roll system. This application system enables excellent coating and size profiles even at high speeds. Its use increases the operating window of PM 6 and offers Smurfit Kappa more production flexibility. The SpeedSizer ensures an increase in the solids content of up to 17 percent and reduces the moisture ingress into the paper web. This results in a higher dry content downstream of the SpeedSizer AT, which helps substantially reduce drying energy and achieves much improved paper web running properties.
Voith used a Nipco roll that was already being used in the old puddle-type size press as a deflection compensation roll. Following comprehensive reconditioning, they now also ensure optimum CD profiles and consequently high paper quality from the new machine as well. The re-use of the previous rolls reduced the costs of the upgrade.
The new SpeedSizer AT also plays a major role in reducing the energy consumption of the PM 6. Immediately, a 15 percent reduction in steam consumption was achieved. The specific energy figures are also improved as a result of the higher production rate.
