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UMV HEADLINES 1
UMV HEADLINESTotal focus on coating
& drying
2 UMV HEADLINES
Supplying complete coating anddrying systems is our total focus atUMV Pulp & Paper today. Andwhy not? Forty years experience ofdeveloping, marketing and sellingequipment for sizing and coatingof paper and board, complementedby a top-of-the-line range of dryingsystems, puts us in a position to offercoated board and papermakersunique, productivity-increasingcoating and drying systems.
Coating and drying hardware and softwareSince Billblade hit the market in the 1960s, we have introduced a
long line of other unique, space-saving and productivity-
increasing products to the market that apply various technologies
including ABC blade profiling, TWIN-HSM and Mirroblade
and TWIN-Gravure roll premetering and coating as well as LAS,
decurlers and moisturizers.
In addition to this extensive range of sizers and coaters,
UMV offers board and papermakers all of the equipment
necessary for complete drying sections.This includes drive systems, framing design, web turns, tail
feeding systems, electric and gas infra-red dryers, drying cylinders,
“Our focus is completecoating and drying systems…
Infra-red dryer Infra-red dryer
ABC Coater#5 coatsback sideof top layer
ABC Coater#4 coatsback sideof top layer
Pope reeland stand
ducting and venting, web cutters, popes and reel stands.
In other words, we offer coated board and papermakers all
the hardware needed for efficient, productivity increasing coatingand drying sections. But that’s not all. We also offer the process
knowledge and expertise gained from forty years in the business
in the form of control systems, service agreements and consulta-
tion for optimized coating and drying operations. In other words,
UMV offers all of the ingredients for the supply of turnkey coat-
ing and drying systems – almost all.
An advanced pilot plant availablefor customers and third partiesIn our view, a complete supply of turnkey coating and drying sys-
tems also involves trials run in the advanced pilot plant we oper-
ate. Designed to correspond with actual mill operation and pro-
vide results that accurately duplicate commercial conditions, our
state-of-the-art plant saves time and money. No production is lost
while running trials on full-scale machines or while educating and
training of staff to operate coating and drying systems.
The UMV pilot plant is available for potential and previousUMV customers as well as for third parties such as chemical com-
panies and paper and board mills
needing to test new products on
base papers of their own choice,
and/or educate and train staff.
UMV is not only an
experienced but also a complete
supplier of turnkey coating and
drying systems. ●
Louise Törnefalk SvanqvistPresident, UMV Pulp & Paper
The cover of Headlines is printed onFrövi White 240 g/m2, an all-whiteboard featuring excellent printing anddesign properties on both sides.
UMV HEADLINES 3
UMV Pulp & Paper is responsiblefor the installation of the completecoating section, web handling andpope reeler for the new boardmachine at Ningxia Meili Paper CoLtd in Ningxia Province, China.
The coating section for the 4880 mm wide machine, which oper-ates at 800 m/min to produce 970 tpd of coated board, consists
of six coating machines – five ABC Coaters and one TWIN-
HSM as well as IR dryers. The raw material for production comes
from the mill’s own poplar tree plantation.
The UMV involvement in the project also includes overall
design review as well as drying calculations for the standard cylin-
der drying equipment supplied by the Shandong Changhua Paper
Machinery Co.
“Our involvement in this project is a perfect example of whowe are,” says Louise Törnefalk Svanqvist, president, UMV Pulp &
Paper. “Supplying state-of-the-art equipment for sizing and coat-
ing of paper and board, complemented by a top-of-the-line range
of drying systems. And, apart from equipment we supply process
knowledge. This is UMV Pulp & Paper. We contribute not only
equipment but also our extensive experience and skills to projects
like this.
“I might also add that it gives us great pleasure to work with
the Ningxia Meili Paper Co Ltd. It is their mission to find thebest suppliers of paper machine equipment and expertise in order
to provide their operations with optimized machinery at an
…and the Ningxia Meili project isa perfect example of who we are”
affordable cost. We are happy to participate in projects with these
kinds of intentions.”
Scope of the UMV delivery
• One TWIN-HSM pre-metering station
• Five ABC Coaters employing UMV Automatic Blade Control
(ABC) technology
• The web handling system including the web turner and tail
feeding system
• The infra-red drying system for the five ABC Coaters
• Pope and reel stand for rolling and unrolling for winding and
unwinding
• Control systems for all of the above for the complete scope
• Complete drying calculations for the standard cylinder drying
equipment supplied by the Shandong Changhua Paper
Machinery Co. ●
Infra-red dryer
ABC Coater#2 coatsback sideof top layer
ABC Coater#3 coatsback sideof top layer
ABC Coater#1 coatsback sideof top layer
TWIN-HSMsurfacesizing andpigmenting
Fourteendryingcylinders
The pope reel in its distinctive Ningxia Meili Papergreen in the UMV shop previous to delivery.
4 UMV HEADLINES
P neumatic blade tip loading is the
key to the simplicity of the ABC
blade profiling system. Compli-cated mechanics such as stepping motors
and position transducers and a lot of elec-
trical components have been intentionally
designed out of the ABC to minimize
maintenance and ensure years of depend-
able service.
Low cost, versatile andtrouble-free operationOn the other hand, a number of produc-
tivity increasing features have been de-
signed into the profiler. Initially very af-
fordable, in the long term the ABC is in-
expensive to operate and maintain. Instal-
lation on a new or existing blade beam is
effortless, which minimizes installation
time.ABC features versatility. It can be op-
erated in stiff blade, stiff bent blade, con-
ventional bent blade and rod modes to
coat papers ranging from LWC to heavy
board in coat weights as high as 25 g/m2.
Automatic operation is a given. But
manual operation is an option for a tight
budget without having to sacrifice perfor-
mance. Fully automatic operation can beadded later.
The ABC requires no specialized op-
erators and when working under auto-
matic/computer control it can be left vir-
tually unattended for long periods of time
allowing operators to focus on other criti-
cal papermaking tasks.
AS EASY AS ABCThe ABC blade profiling system has been described as operator-friendly,clear-cut, straightforward, trouble-free and undemanding. The truth ofthe matter is easy – easy as ABC when it comes to gaining excellent coat-weight control and gaining the benefits of straightforward operation.
The pneumatic blade tip-loading featureof the ABC system provides “selfpositioning” relative to the backing rolland the paper. This means that bladebeam deflection during startup doesnot affect the coat weight profile. Inother words, the ABC self positions theblade to provide uniform coating colordistribution. This results in initialprofiles twice as good and achieved inhalf the time as required by any othertype of profiling system.
Instantaneous flat CD profilesThe pneumatic blade tip-loading feature
of the ABC system provides “self position-ing” relative to the backing roll and the
paper. This results in initial profiles twice
as good and achieved in half the time as
required by any other type of profiling sys-
tem – a real cost reducer.
In fact, the ABC system provides cor-
rect coat weight levels and excellent CD
profiles long before scanner and closed-
loop systems are in control mode. Con-
stant control of the coating process is theresult of the stable and repeatable ABC
blade loading system.
Control begins when the blade con-
tacts the paper. At this point the ABC en-
sures the same blade tip angle at every
point across the web and the same tip
angle over time.
Therefore, the quality of the coatedpaper is constant from front to back and
from start to finish. What’s more, quality
is not affected by blade wear. The absolute
ease of setting the parameters also ensures
the expected results when returning to a
specific grade. ●
UMV HEADLINES 5
T he three mills produce coated
woodfree (CWF) papers in basis
weights ranging from 90 to 250
g/m2. Headlines asked Mr. Stefani why hefavored ABC technology over the other
coating profiling technologies available on
the market today.
He comments:
There are any number of reasons why
I liked ABC when it was first introduced
to me. But most important was the ex-
tremely comprehensible way the systemworks. It’s very, very simple – mechanically
uncomplicated. Put it this way, what’s not
there is not causing any trouble.
The more technical equipment you
can eliminate from a coating system, the
simpler it is to operate and maintain, and
the ABC is not complicated – just air bel-
lows. No complicating factors such as
stepping motors and position transducers.The ABC allows gaining uniform
CD profiles very quickly at startups,
which eliminates the production of non-
spec paper. The pneumatic actuators refer
to the paper and the backing roll rather
than the deflected beam during startup. In
other words, the ABC self positions the
blade to provide uniform coating color
distribution.
When the challenging environment
in which coating systems operate is taken
into consideration, the absence of compli-
cated mechanics and a lot of electricalcomponents favors operational availability
and machine runnability.
In terms of performance, the ABC is
comparable with the most sophisticated
coating systems in the world. But the dif-
ference between ABC and the other op-
tions in my view is trouble-free operation
and maintenance and unproblematic partsreplacement.
The Burgo group, based in Vicenza, Italy, is a leading producer in southern Europe ofcoated woodfree (CWF) and woodcontaining (CWC) paper used for printing of catalogs,magazines, commercial matter and books. Pictured is PM 2 at the Burgo Sora mill.
ANTONIO STEFANI FROM BURGO:
ABC makes believersof skeptics at BurgoAntonio Stefani, associate vice president, technol-ogy and investments, played an important partin the decision to purchase the six ABC bladeprofiling systems fitted on the three off-linecoaters at the Burgo Avezzano and Sora mills,after the two installed on the on-line coater onthe paper machine at the Sarego mill. All of theABC profilers have been installed since 2000.
Non-specialist staff can operate and
maintain the ABC. It’s flexible and doesn’tpresent operators with a lot of parameters
to play with. It can be operated very suc-
cessfully in both stiff and bent blade
modes.
As regards spare parts, there are few
of them and they are standard. Those
needed are not special in any way, and
they are available from just about anyreputable supplier.
The ABC is designed also as a retrofit
and again, in this respect, it is simple. In-
stalling it is as easy as drilling and tapping
a few holes. That’s it.
Regarding costs, the initial cost is
definitely affordable and operating costs
minimal. Acceptable CD and MD profiles
after startups or grade changes are reachedalmost immediately, a factor that allows us
to produce more saleable paper instead of
reject.
My decision in favor of ABC tech-
nology was first met with skepticism. It
could be that this attitude was based on
prejudice against simplicity. Skeptics can
say “too simple. Anything that simple can’tbe good!” Now the skeptics are confident
in the system and they view it as beneficial
in spite of its simplicity. Or most likely,
because of its simplicity. ●
6 UMV HEADLINES
Antonio Di Blas, production manager, and Vittorio D’Olif, coatingtechnical manager explained for Headlines the coating system generallyand how two ABC coating profilers specifically contribute to greaterproductivity at Cartiere del Garda fine paper mill. Their comments:
ANTONIO DI BLAS AND VITTORIO D’OLIF, CARTIERE DEL GARDA:
“ABC contributes togreater productivity”
Cartiere del Garda, a member of the
Lecta Group, has a capacity of 340,000
tons of woodfree coated paper. Strate-
gically located at the most northern
point of Lake Garda, Cartiere del Garda
has easy access to markets in northern
Italy as well as Central Europe.
UMV HEADLINES 7
A t Garda Cartiere we strive to gain stability in all of the
processes. In our view, stability is the key to manufac-
turing high-quality products at the lowest possible cost.
To achieve stability, we have established benchmarks for the vari-
ous parameters of each process, and the staff checks daily to de-
termine if they are being met. The result has been greater controlover the processes and improved productivity.
On PM 3, we pre-coat intermediate and low basis weights
on two standard on-line blade coaters. Top coating is off-line on
two blade coaters fitted with ABC profilers installed in 2005.
On PM 2, we pre-coat intermediate and high basis weights
on line with a roll coater and two blade coaters with ABC
profilers installed in 2002. Top coating is off-line on two stan-
dard blade coaters.
The first experience with ABC profilers on PM 2 has been
very good. We have increased the coating color application all
over the width of the production range of the machine.
Actually we are able to reach 30 g/m2 in stiff mode with anoptimum profile control also at a very low speed, and, adding
coating color is cheaper than increasing the basis weight of the
base paper to achieve a higher weight of the final paper.
The operating angles of the beam can be set quickly and
with reliability of service. This aspect is very important for an
on-line coating machine, because it gives high flexibility in
changing blades geometry without loosing too much time for
adjustments and calibrations. The perfect management of theoperating angles reduces the risk of stripes and other surface
defects.
Also the time needed to reach good profiles and standard
coating color applications has been dramatically reduced, so
that the production has increased.
Starting from the good results of this experience, three
years later we have decided to rebuild the off-line coating
machine with new coating circuits, new jet applicators, and
new ABC profilers. This rebuild has been really a big challengefor us: the main goals were increasing speed, increasing flexibil-
ity and above all, increasing quality.
Today this coating machine runs perfectly aligned with the
expectations: speed and flexibility are not limited any more and
the quality of the top coating process is very good. Some doubts
concerning the stability of the pneumatic profiler when the fly-
ing splice passes through the coating heads at high speed (1400
m/min) have today disappeared.
The ABC profilers have contributed greatly to helping usachieve our goals and this has increased productivity.
The pneumatic system and the geometry of the blade and
the blade holder system and the absence of electric components
in a coating environment contribute to the simplicity of the
ABC profiler when compared with standard coaters. We think
it is easier and safer to operate and to maintain in this kind of
environment.
On the ABC profilers we use both steel and ceramic bladesfor coating in stiff blade mode. The ABC profiler has increased
the lifetime of steel blades, which has reduced downtime from
blade changes from 0.5 to 0.3% of the total running time.
What is more, because of lower blade pressure, the ABC
profiler has increased the lifetime of backing rolls by 50 to
60%. Again, this means an increase in productivity. ●
Antonio Di Blas, productionmanager, and Vittorio D’Olif,coating technical manager:“ABC has contributed to greaterproductivity at Cartiere delGarda. What else can we say?”
8 UMV HEADLINES
UMV GRAVURE COATING TECHNOLOGY:
Low coat weights at high solidscontent, superb surface qualityThe application of rotogravure printing technology to time-provenUMV Billblade and TWIN-HSM technology allows applying coatweights as low as 6 g/m2 at solids contents of 68% or higherwith excellent coating color distribution and surface quality.
S tarch can be applied at higher solids levels than those pos-
sible for any other metering size press on the market with
out “patterning” at the point of application.
Similar to the flexographic principle used for rotogravure printing,
the surface of the gravure-coating roll consists of small depressionsor cells. The cells are completely filled with fluid at the point of
coating color application. Excess fluid is doctored off the gravure
roll surface using a soft-tipped doctor blade. The coating fluid is
then transferred to the transfer roll in the metering roll nip and to
the paper in the transfer roll nip. See Figure 1.This technology is available from UMV in two formats: the
TWIN-Gravure for two-side coating or the MONO-Gravure for
one-side coating.
Coat weight controlCoat weights are adjusted by controlling either gravure roll speed
(volumetric) or blade pressure (hydrodynamic). The volumetric
method is preferable for low coat weights such as surface sizing,
pigmentation and coating. The hydrodynamic method extends the
coat-weight range. Truly flat CD profiles are achieved both in
volumetric and hydrodynamic mode.
When running in hydrodynamic mode the blade pressureprofile across the machine must be adjustable to enable producing
coated paper with excellent CD profiles. Coat weights of 16 g/m2
can be applied with 2-Sigma values of <1 g/m2.
When running in volumetric mode, the coat weight target is
simply “dialed in” in accordance with the surface speed of the
gravure roll relative to the transfer roll. The basic relationship of
volume over time ensures the reprod-
ucibility of results. For any given basepaper there is a direct and linear re-
lationship between the applied coat
weight and the coating solids level
used. See Figure 2.Gaining good two-sidedness when running in volumetric
mode is simply a matter of adjusting the speed of the gravure roll
on either side. See Figure 3. In this case, good two-sidedness was
achieved by increasing the speed of the gravure roll on side two.
Long service life, high availabilityUsing soft tipped doctor blades and applying a nip pressure as low
as possible between the transfer and gravure roll virtually elimi-
nates wear on the TWIN-Gravure roll surface. Low nip pressure
lengthens the service life of the transfer roll surface as well.
The TWIN-Gravure ensures excellent machine availability.
Minimal machine downtime is secured by changing the gravure
pre-metering rolls annually at scheduled maintenance stops andutilizing long life soft tip blades to doctor off the excess fluid on
the gravure roll.
Reduced energy consumptionTWIN-Gravure allows applying starch at high solids levels. For ex-
ample, 1 g/m2 dry can be applied at 25% solids, reducing drying
energy by 75% compared to conventional metering size presses.
However, it is also possible to apply 1 g/m2 at 10% solids if this is
to be preferred for any reason. ●
Figure 3: Increasing the speed of the gravure roll on side twoprovides equal appearance on both sides.
Figure 1:Gravure pre-metering.
Coat weight 8.0 g/m2 8.0 g/m2 8.0 g/m2 8.0 g/m2
Gravure speed 72% 72% 72% 72%
Basepaper
Side 1 Side 1 Side 1 Side 1 Side 1
Side 2 Side 2 Side 2 Side 2 Side 2
Gravure speed 72% 75% 80% 85%
Coat weight 7.9 g/m2 8.0 g/m2 9.0 g/m2 9.3 g/m2
Figure 2: The higher thegravure roll speed, thegreater the coat weight.
Coatweight
Gravureroll speed
UMV HEADLINES 9
AT KORSNÄS FRÖVI:
MONO-Gravure technologymakes Frövi White possibleLuxury products require luxury packaging – all-white board featuringa uniform printing surface, good design and printing qualities on thefront as well as on the reverse side. And that’s Frövi White, the onlyproduct with a coated reverse side in the Korsnäs range of products.
T he target group for Frövi White is luxury products, and to
obtain this board grade Korsnäs invested in a MONO-Gra-
vure coater from UMV Pulp & Paper at its Frövi mill to
enable reverse side coating. Previous to this investment, most of
the board produced at Frövi had a brown reverse side with the ex-
ception of Frövi Bright, which has a reverse side of bleached pulp.Frövi White, with a reverse side of coated bleached pulp, is
whiter than Frövi Bright and its printing surface is considerably
better and more uniform. The target while developing Frövi
White, according to Tommy Andersson, R&D specialist in the
area printing, was to increase whiteness by 40%. Frövi White is
also stronger and more formable than Frövi Bright, a product
highly regarded for these properties.
“We invested in the gravure coating system to gain a niche
between fully bleached board and GC1 (reverse side coated FBB).An investment of this order had to be well founded, and a market
analysis clearly indicated what customers want. After 15 pilot
runs in the UMV as well as our own pilot plant we were able to
deliver,” says Ola Karlsson, project leader for Frövi White.
Frövi White was developed to attain perfect printing results,
enabling upmarket graphic display. Its extraordinarily smooth
printing surface is achieved through the construction of the base-
board and by way of advanced coating technology.Frövi staff selected the gravure coater not only because of the
quality of the printing surface it produces on the reverse side of
Frövi White, but also for a number of other reasons.
“We get high-quality surfaces by applying half as much coat-
ing color at high solids content. This lets us run the board machine
more economically. This factor affects productivity positively.
“The coater provides an excellent coating surface at low
pickup.
“Versatility was another reason we invested in the gravurecoater. Coat weights can be easily varied, it can be efficiently used
to surface size or coat other products in our total range and, with
the purchase of some additional equipment in the future, it can be
fitted for double coating and sizing,” says Lars-Erik Mellgren, mill
technology manager.
Previous to the installation of the gravure coater, Frövi coated
top surfaces twice with three blade coaters. To enable reverse-side
coating, the gravure coater replaced the first blade coater. Top coat-ing of Frövi White is carried out on the remaining two blade
coaters fitted with UMV ABC profilers. ●
UMV MONO-Gravure coating technology at Korsnäs Frövi.
Torbjörn Widmark, product development manager and responsiblefor pilot coating beside the pilot MONO-Gravure coater in the fullyequipped pilot plant at the Korsnäs Frövi mill.
10 UMV HEADLINES
■ “Being able to monitor coating color properties is a distinct
advantage. It’s like a fire alarm. The CCM allows identify-
ing deviations from set values to gain stable solids content.
It also enables us to predict the risk of skip coating due to
high entrained air content as well as predicting low coat
weight as a result of low solids content.
■ “Accurate and reliable measurement of solids content, vis-
cosity and entrained air content also minimizes production
losses after faulty startups. It’s easy to use too. Calibration is
automatic and it measures solids content every five min-
utes,” says Mr. Jansson.
■ Earlier attempts at monitoring coating color failed. Theobstacle to accurate and reliable measurement was being
able to predict the air content of the coating color. This
hindered measuring solids content and viscosity. The CCM
overcomes this problem.
■ Comparison of CCM values vs. lab samples from Coating
station 3 at Frövi shows that solids content deviated over
a three-day period by <0.2 on average.
■ “In fact, the CCM might provide truer values than the lab
due to the fact that the lab has a problem with entrained air.
■ “The CCM measures up to the task,” says Mr. Jansson. ●
CCM measures up to the task
The UMV Coating Color Monitor. “The CCM gets the job done,”says Niklas Jansson, process engineer at Korsnäs Frövi.
The Coating Color Monitor (CCM) from UMV Pulp & Paper andS-Tec AS positioned before the circulation tank at Korsnäs Frövi worksvery well according to Niklas Jansson, process engineer at the mill.
UMV HEADLINES 11
UMV infrared drying systemscomplement the full rangeof UMV coating systemsUMV infrared drying systems, the result of long experience and continualdevelopment in the drying of coatings and moisture profiling, are an excellentcomplement to UMV coating systems.
The electric powered Itronic HET (High Energy Temperature) heat module from UMV dries coating fast andeffectively reduces mottling caused by drying and eliminates smearing on rolls and drying cylinders.
A vailable in an electric-powered version from UMV and in
gas-powered versions from other suppliers such as Mars-
den, the IR systems effectively reduce mottling caused by
drying and eliminate smearing on rolls and drying cylinders.
The electric powered Itronic HET (High Energy Tempera-
ture) heat module when used for drying coating results in fast andeffective drying.
UMV also offers coated paper producers the gas-fueled
Marsden IR dryer featuring the unique Embedded Combustion®
Emitters to produce high conversion to radiation efficiency.
Both the UMV electric powered Itronic HET heat module
and the gas-fueled Marsden IR dryer dry quickly and from within
the coated surface to prevent binder migration and mottling.
Continuous moisture profiling in both coaters and paper/
board machines is another benefit of these dryers. Both dryers fea-ture field bus technology for easy connection to and remote con-
trol from DCS/QCS systems as well as user-friendly operator inter-
faces based on standard PLC operator panels. ●
12 UMV HEADLINES
IR drying puts Oppbogain a niche marketSatisfying the need for top-of-the-line, twin-sideddisplay board in small quantities with short leadtimes to the graphics industry is what Oppbogacan do and what big board producers cannot do.
O ppboga manufactures, markets and sells tailor-made,
twin-sided board for advanced packaging where the
demand for excellent printing on both sides is needed.
Oppboga also promotes artists and photographers by offering the
market a range of passe-partout and backing boards.
“We laminate these boards in two to five layers in basis
weights ranging from 300 to 2200 g/m2. We export about 75% ofour production mostly to other countries in Europe, but also to
Australia and South Africa. The rest is sold on the domestic mar-
ket,” says Björn Grage, production manager at the converting
plant.
Production at the Oppboga Bruk, located about 100 km
west of Stockholm, is on two laminating lines complemented by
guillotines, sheeting and wrapping machines.
“Flat profiles are a must for meeting our customers require-
ments. Twin-sidedness and high basis weights are important prop-erties for our customers, but flatness is an absolute requirement
for them. Providing our customers with flat profiles permits us
The bulldog ispart of the Opp-boga trademark,and like a bull-dog, Oppbogaexemplifiesstrength,determinationand personality.
to operate in our niche market,” says Mr. Grage.
Electric infrared drying stations from UMV are the key to
flat board from Oppboga. There are four IR drying stations on
Line 1 and two on the new Line 2.
Mr. Grage explains why they are so important:
“We purchase all of the board we laminate in rolls. The IR
dryers are positioned directly after unrolling. They are used toheat the board to the perfect temperature for activating the lami-
nation glue. To achieve flatness, we use the dryers to moisture
profile the incoming and outgoing board.
Each row on the new IR dryers is fitted with 14 Heat Energy
Temperature (HET) modules. Each module is divided into two
75 mm drying zones to provide optimal moisture profiling.
“Our niche market is display and packaging board designed
to carry printed messages. Printing requires flatness. We can’t pro-
duce board that satisfies our customers’ needs without well func-tioning IR dryers. It’s that simple,” says Mr. Grage. ●
“Our niche market is display and packaging board designed to carry printed messages. Printing requires flatness. We can’t produce board thatsatisfies our customers’ needs without well functioning IR dryers. It’s that simple,” says Björn Grage, production manager at Oppboga Bruk.
UMV HEADLINES 13
D alum is known as one of the world’s most environment-
friendly paper producers. The product range there consistsof matt-coated paper and uncoated printing and writing
grades. The papers come in two recycled variants – Cyclus, com-
prising 100% recycled fiber, and RePrint – FSC Certified, contain-
ing a minimum of 50% recycled fiber together with virgin fiber
from sustainable forestry.
“We produce electrical energy on site in bio-fueled steam
boilers for the paper machines. Excess steam from steam pressure
drops produce about 60% of the electricity we require. The rest we
purchase from the grid.“If we had a shut down to do maintenance on the steam tur-
bine or the bio-fueled boiler, we had to stop one of the paper ma-
chines, or not use the electric IR, instead produce uncoated paper
on the machine, because the electric power transmission lines from
the local grid can’t manage to transport the power needed. We also
have the possibility to produce electric power on a condensation
turbine. “Both options are expensive and therefore affect produc-
tivity negatively. Therefore, under these circumstances, we have to
shut down a machine,” says Claus Christiansen, maintenance engi-neer at the mill. This was the case all to often before Dalum
switched over from electric to gas-fired infrared drying on PM 7.
“Studies of the various options told us that gas drying would
enable us to run normal production. And we’ve got a lot of gas in
Denmark so that was the obvious choice.
“Therefore, we made the switch and now we can run both
machines at the same time. The gas-fired dryer has reduced down-
time considerably,” says Mr. Christiansen.According to Mr. Christiansen, after eight months of opera-
tion, ongoing calculations show that the gas system UMV installed
has meant greater energy cost-saving than any other gas-fired or
electric infrared options they considered installing.
“We use the dryer strictly for drying. The embedded combus-
tion feature of the gas dryer means quick drying from within thecoated surface and this gives us good control of binder migration.
Good moisture profiling is also an added benefit of the installation
because it improves surface quality. Both improvements mean bet-
ter overall product quality.
“The dryer is also easy to maintain and lower temperatures
around it mean better working conditions. It also cools down
quickly after being shutdown, for example, after a web break.
“Most importantly, with the right energy mix we can producepaper on both of our machines at the same time. And that’s our
business,” says Mr. Christiansen. ●
Optimal uptime for the two papermachines at Dalum Papir in Den-mark was the target when the millinstalled gas fueled-infrared dryingon PM 7. Optimum production theredepends on a 60 – 40 energy mix splitbetween electricity produced on siteand that purchased from the grid.
“Studies of the various options told us that gasdrying would enable us to hit our target of a 60-40split. And we’ve got a lot of gas in Denmark so thatwas the obvious choice,” says Claus Christiansen,maintenance engineer at Dalum Papir.
Gas-fueled IR dryingoptimizes energymix at Dalum
14 UMV HEADLINES
MIRROBLADE:
It’s compact and quality coatstwo sides simultaneouslyThe UMV Mirroblade is compact and it blade coats two sides simultaneouslyBut that’s not all. It provides equal side-to-side coverage up to 20 g/m2 withno film split pattern, mottle or curl. Because it applies the UMV ABC bladeprofiling system in a mirror image of each other, one on each side of the web,it’s easy as ABC when it comes to gaining excellent coat-weight control andgaining the benefits of straightforward operation.
Two blades, one on each side of the
web, separated only by the thickness
of the paper – a concept made pos-
sible by the ABC blade-loading principle
and soft-tip coating blades.
Precision control of the blade tipAn ABC blade profiler loads the blade atthe tip to keep the blade completely
straight during all phases of operation and
for all blade pressures and angles. The blade
never bends. The position and angle of the
blade tip is always known and under per-
fect control resulting in precise and reliable
blade tip alignment.
The Mirroblade’s small footprint is the
result of this profiling concept. Profiling isachieved by adjusting the blade pressure of
the opposing blades against each other, and
by the many individual pneumatic actua-
tors that respond instantaneously to signals
from the control system to apply uniform
pressure across the width of the web.
The forgiving soft tip bladeThe ABC blade profiling system is one in-
novation making the Mirroblade possible.
The other is the revolutionary soft tip
blade. The soft polymer blade tip yields the
coating nip forgiving to impurities and
defects in paper, a fact that also reduces
web breaks and downtime.
Figure 1. In an upward configuration,Mirroblade blade coats base paper in therange from 60 g/m2 upward. Machine speedis unlimited. Different types of media canbe applied on the top and reverse sides ofthe paper in this configuration. With theweb running downward, Mirroblade bladecoats base paper in the range from 60 to230 g/m2. The maximum machine speed is700 m/min.
Unprecedented fiber coverage is an-
other feature of the soft-tip blade. The
micro contouring allowed by the deform-
able blade tip leaves no fiber surface uncov-
ered. The result is excellent printability and
a mottle-free coating surface.
Superior surface qualityAs a pre-coater, Mirroblade eliminates the
misting and film-split pattern problems
associated with metering size presses be-
cause it has no roll to create these problems.
Mirroblade also permits applying very high
coat weights. As a middle-layer coater for
triple coating or as a top coater, the
Mirroblade is the only system that can coat
both sides in one pass. A metering size presscannot produce acceptable surface quality.
Uncomplicated and fitsalmost anywhereMirroblade coats paper or board up to 20
g/m2 in a space less than one-third the size
of the most efficient two-station layout.
And because it has no drives, Mirrobladeeliminates the difficulties of motor and
gearbox placement. It can be placed almost
anywhere, and installed either with the web
running upward or downward (Figure 1).
Low investment costCompared to a conventional two-station
installation, Mirroblade, including the
necessary auxiliary equipment for web
handling, requires about one–third the in-
vestment cost. Less equipment to install
and less existing equipment to move means
low installation costs and short installation
time. ●
UMV HEADLINES 15
The inside pages of Headlines are printed onGrycksbo ArrowMatt 115 g/m2 a wood-free, coatedpaper for demanding image reproduction.
two-station blade coatinglayout. “A two-station
layout would have meant
lengthening the paper
machines. So the choice
of Mirroblade was
tempting because we
could fit them into
the same space requiredfor the previous coaters. This answer
to our problem was also less expensive.
Mirroblade also gave us other benefits.
Wide coat-weight range“The UMV ABC technology applied to
the Mirroblade allows applying heavier
coating weights than traditional blade
coaters – as much as twice as much.Applying this much coating with tradi-
The Grycksbo team (left to right) HåkanKarlsson and Susanne Öhman from UMVand Åke Olsson, Jan-Olof Göräng andJan-Erik Wikén from Grycksbo.
“The potential benefits of the Mirrobladeoutweighed the risk, and now, looking backover 10 years of experience of Mirroblade,I have to say we won,” says Åke Olsson,production manager at Grycksbo Paper.
10 successful years withMirroblade at Grycksbo PaperIn the spring of 1997 UMV installed a Mirroblade coating station on PM 9at the Grycksbo Paper fine paper mill in Sweden. A year later a secondMirroblade was in operation on PM 7. Mirroblade technologypermits blade coating both sides of the paper simultaneously.
tional blade coaters would require four
coating stations. With Mirroblade, we can
compete in the double-coated market
while producing on a lot less machinery,”says Mr. Olsson.
Installing the first-ever commercial
scale Mirroblade involved risk. Not only
was it the first two-side coater of its kind,
it also employed brand-new soft-blade
technology. So, according to Mr. Olsson,
operational availability caused by running
in problems was a consideration.“But the potential benefits of the
Mirroblade outweighed the risk, and now,
looking back over 10 years of experience
of Mirroblade, I have to say we won.
Availability is very high. The coaters coat
both sides at once. They’re safe, quiet and
reliable and provide equal side-to-side cov-
erage with no film-split pattern, mottle or
curl. And the soft tip provides excellentfiber coverage,” says Mr. Olsson. ●
“We took the risk of putting the first-
ever Mirroblade into commercial
operation and 10 years of successful coating
is the proof that we won,” says Åke Olsson,
production manager at Grycksbo Paper.
Grycksbo Paper produces two differ-
ent paper grades. Both are woodfree and
matt coated. G-PRINT features a white,matt-coated surface and high opacity and is
available in sheets and reels in grammages
from 80 to 250 g/m2. ARROW MATT is
designed to provide excellent printability in
combination with high bulk. It is available
in various sizes in grammages from 90 to
250 g/m2.
CompactThe Mirroblade coater on PM 7 replaced a
TWIN-HSM, and a Billblade coater on
PM 9. The Mirroblade coaters provided the
mill with blade coating on both machines.
“To remain competitive we had to
produce paper that was blade coated on
both sides. The earlier coaters were com-
pact. Like the Mirroblade, they requiredless than one-third the space necessary for a
16 UMV HEADLINES
UMV Pulp & Paper operates oneof the most advanced pilot plantsin the world for developing andoptimizing coating and sizing andother surface treatment processes,machinery and products.
Advanced pilot plant benefits
D esigned to correspond with actual mill operation and provide
results that accurately duplicate commercial conditions, the
state-of-the-art plant is very beneficial when it comes to educat-
ing and training of staff working with surface-treatment equipment.
And it’s available! For potential and previous UMV customers as
well as for third parties such as chemical companies and paper andboard mills needing to test new products on base papers of their own
choice, and/or educate and train staff.
Education and training in a pilot plant a money saverConducting education and training in a pilot plant is also a money
saver. Compared with carrying out this task on a mill’s own machinery,
education and training in a pilot plant enables operating at the extremes
as well as at correct levels to show trainees how they can most efficiently
operate coating and sizing equipment.What’s more, they can and compare and contrast the results from
runs on the various technologies available on site, without losing a milli-
meter of production!
Fully equipped plant and knowledgeable staffThe staff in the plant is extensively experienced and knowledgeable and
complements well UMV’s intention to make the fully equipped, state-
of-the-art pilot plant available to customers and third parties.The pilot machine runs at speeds of up to 2200 m/min. It accom-
modates not only conventional surface treatment processes, but also the
UMV innovative range of coating and sizing technologies (Figure 1).The full range consists of Mirroblade upward and downward
coaters, the ABC blade coating station, ABC-Gravure combined roll
With customer’s valuable time and money in mind, pilotplant staff makes sure that changing from running one typeof application to another takes place quickly.
UMV HEADLINES 17
UMV customers and third parties
Figure 2. The full range of UMV proprietary coating and sizingtechnology. With customer’s valuable time and money in mind,pilot plant staff makes sure that changing from running one typeof application to another takes place quickly.
premetering and blade coater, the LAS decurler and moisturizer, theTWIN and MONO Gravure coating systems, the TWIN-HSM roll
coating and sizing system, as well as the Billblade coater (Figure 2).The drying and web handling system on the pilot machine consists
of one electric IR and three air float dryers. An on-line measurement
and quality control system measures total coat weight and also the coat
weight on each side of the paper.
The plant has experience of coating and sizing virtually every grade
of base paper currently available such as NCR copy paper, board andfine paper as well as coating and surface sizing of liner board and fluting.
A climate-controlled lab for standard testing of properties such as
IGT, A1C5, Hunter gloss, Bendtsen, PPS, Alwetron TH-1 tear strength
and quick ash is also available.
With customer’s valuable time and money in mind, pilot plant staff
makes sure that changing from running one type of application to an-
other takes place quickly. For instance, if a pilot run on a TWIN-Gra-
vure tests pre-coating and then is followed-up by runs on an ABC for
top coating, the waiting time between the runs is minimal. Time ismoney. ●
Figure 1. The UMV pilot machine is equipped withstate-of-the art technology. It accommodates notonly conventional surface treatment processes,but also the UMV innovative range of coating andsizing technologies.
Actual samples of the newly developed product from pilottesting are a very helpful marketing and sales tool.
Mirroblade DW
Mirroblade UW
TWIN-Gravure
ABC Gravure
ABC Coater
Billblade
LASTWIN-HSM
The staff in the plant is extensivelyexperienced and knowledgeable andcomplements well UMV’s intention tomake the fully equipped, state-of-the-art pilot plant available to customersand third parties.
P I L O T M A C H I N E S P E C I F I C A T I O N S
DRIVE SPEED:2,200 m/min (7,218 ft/min)
ACTUAL MACHINE SPEED: 2,000 m/min (6,562 ft/min)
DRYING CAPACITY:2 x 10 g/m2 coat weight at 55% solids
and 6% end moisture at 2,000 m/min
ON-LINE PAPER-QUALITY CONTROL: ABB Smart Platform/
AccuRay 1190 IR system for on-line measurements of basis
weight, moisture and IP absorption spectroscopy of coat weight
at the unwind and rewind positions of the pilot machine.
18 UMV HEADLINES
Ylyva Wildlock, Group Head, R&D, Pulp andPapers Systems Application led a delegation ofEka staff to the UMV Pilot Plant. Their task wasto test a new coating-chemical formula to learnwhere and how it can best be applied in commer-cial operation. Ms Wildlock told UMV Headlineswhy she thinks pilot testing is beneficial.
T he first thing that comes to mind
when I consider the benefits of pilot
testing is the elimination of risk and
high costs. The alternative to pilot plant
testing is testing in our own laboratory or ona commercial scale machine. The gap be-
tween how a new product responds to vari-
ous parameters in full-scale operation and
laboratory testing is obvious. Testing in a pi-
lot plant is the best way to narrow the gap.
Apart from producing a lot of expen-
sive broke, testing on commercial scale ma-
chinery is impractical in other ways. For in-stance, a mill may offer the possibility of
testing on a single technology, say a blade
coater or on a rod coater. Testing on other
technologies would involve moving from
one full-scale mill to another, needless to say,
a costly process. What’s more there is a great
possibility that we won’t be running on the
same base paper grade making comparison
difficult.
Freedom to test various parametersTesting a new product in a pilot plant such
as the one UMV offers potential customers
as well as third parties minimizes risk and
keeps costs at an affordable level. The plant
with its virtually the full range of coating
machinery, gives us the freedom to test vari-
ous parameters, such as coat weight, coatingcolor formulation, machine speed, drying
properties, etc, on the different technologies.
The pilot offers us two drying tech-
nologies, electric IR and gas-heated air dri-
ers, which allow for testing of various drying
scenarios.
It’s important to note that testing of
parameters in the UMV pilot plant is car-
ried out under complete control and under
the watchful eyes of a very skilled and com-
petent staff – and often on a single roll ofbase paper!
Testing a new product in an advanced
pilot plant minimizes risk because we can
find out exactly what we can expect of the
new product, and the conditions under
which it can be best applied. This is where
risk elimination comes in.
Pilot testing creates marketingand sales toolsAfter trials in the pilot plant, we know so
much about a new product that we can tar-
get precisely which customers we know will
benefit from it. What’s more, as a result of
the testing, we can show them actual
samples of the newly developed product. In
this sense, pilot testing is also a very helpfulmarketing and sales tool.
So far I’ve only commented on the im-
portance of testing new products Eka has
initiated for use by potential customers. But
the benefits of pilot testing that apply to us
when we initiate a new product also apply
to our customers when they ask us to de-
velop a new product for them, not an un-
usual situation.Pilot testing is a learning experience
that permits us to see under controlled con-
ditions, which closely approximate commer-
cial operations, exactly what we can expect
of a newly developed product.
Eka is an Akzo Nobel company. ●
UMV HEADLINES 19
Ylva Wildlock from Eka:
“Pilot testingeliminates riskand high costs”
The paper betw
een the colored lin
es shows
the various parameters te
sted on this ro
ll.
“Testing ofparameters in the UMV
pilot plant is carried out undercomplete control and under thewatchful eyes of a very skilled
and competent staff – andoften on a single roll of
base paper!”
20 UMV HEADLINES
When it comes to reducing costs, the TWIN-HSM of
fers fluting and liner manufacturers opportunities noother surface sizing equipment on the market can
provide.
Mills previously using conventional size press technology to-
day utilize the HSM to gain better runnability and reduced energy
consumption. Launched on the market in the 1990s, HSM
(High Speed Metering) premetering technology was then regarded
as a great innovation – the first metering size press for C-2-S
applications! Now with more than 70 installations running world-
wide, this technology is proven and reliable.
40% market shareAfter 12 year’s experience of surface-treating base sheets contain-
ing recycled fibers, the HSM was launched in the fluting and liner
market about five years ago as a premetering surface sizer. Since
then, UMV has sold 13 HSMs, for about a 40% share of this
market.
Although the initial cost for this technology is about the
same as for conventional premetering size presses, the return oninvestment is estimated at one year as a result of minimal raw
material and sizing starch costs as well as operational costs because
of high availability and low maintenance costs.
The forgiving qualities of the HSM – minimal risk of foreign
particles collecting in the nip between the premetering element
In an extremely competitive market, enhancing productivity is everyfluting and liner manufacturer’s challenge. Adding value to a productis one way of meeting the challenge, a difficult option when producinga bulk product. Increasing capacity is another way, assuming there arenew markets. Reducing costs is still another way, and probably the bestway for fluting and liner manufacturers to improve productivity.
and the transfer roll – permit the use of low-grade base papers
from recycled raw material.These qualities also allow for applying low-grade sizing
starches to compensate for strength losses when using the low-
grade base papers. Recycled fiber is usually cheaper than other
base-paper fibers, but low-grade sizing starches are even cheaper.
Low vs. high specific pressure at the metering pointThe TWIN-HSM consists of two transfer rolls between which the
base paper runs either upward or downward, and two wire-wound
HSM premetering rolls. See Figure 1.The figure illustrates that the nip between the premetering el-
ement and the transfer roll is large permitting low specific pressure
at the metering point. This feature of the HSM can be compared
with conventional rod surface sizing equipment on which the nip
is considerably narrower and the specific pressure at the metering
point higher. See Figure 2.In practical terms, or to put it another way, in terms of en-
hancing productivity by reducing variable production costs, the
HSMs wider nip and low specific pressure at the metering pointenables using both low-grade base paper from recycled raw materi-
als and low-grade sizing starch to compensate for strength loss.
Why is this the case? Because, the foreign particles in these
materials can pass through the nip, whereas if these materials were
used with conventional rod surface sizing equipment, they would
TWIN-HSM reduces flutingand liner production costs,enhances productivity
UMV HEADLINES 21
collect at the metering point. Therefore, more expensive base
paper and sizing starch, which contain fewer foreign particles,
have to be used with this equipment.
High availability and low maintenance costsThe diameter of the TWIN-HSM premetering element is 30 to
40 times greater than that of a conventional premetering rod, a
fact that means a substantially longer period of time between
refurbishments. Rods and rod beds are expensive and have to
be replaced periodically.
The cost of refurbishing the HSM premetering element can
be as much as 80% lower than that of any other metering size press
technology. This task amounts to replacing the worn wire withabout 15 kg of new stainless steel wire to fully restore a worn HSM
to like-new condition between scheduled maintenance stops. In
other words, no downtime between scheduled stops.
Other productivity enhancing featuresThe greater diameter of the HSM premetering roll is more forgiv-
ing for recycled fibers compared to the metering rod on other
metering size presses. The result is minimal risk of streaks caused
Figure 1. The large nip on the TWIN-HSM permits lowspecific pressure at the metering point to enable us-ing both low-grade base paper from recycled raw ma-terials and low-grade sizing starch to compensate forstrength loss.
by fibers stuck in the nip between
the metering element and the
transfer roll, a value-adding factor.
The special volumetric premeter-ing method of the TWIN-HSM
permits running at high as well as low machines speeds, from as
low as 100 m/min to as high as 1400 m/min.
At low speeds, the TWIN-HSM can apply higher pick up
than any other premetering size press on the market, an important
feature when using low-grade starches to compensate for strength
loss when using low-grade recycled base paper. Compared to the
conventional pond size press, TWIN-HSM premetering technol-
ogy requires less drying and therefore can be run at substantiallyhigher production speeds, a capacity-increasing factor.
Setting up and operating the TWIN-HSM coater is straight-
forward, and controlling pick up, the key parameter, is simple.
Increasing the solids content increases the pick up. Decreasing the
solids content decreases the pick up. Maintaining constant solids
content stabilizes the pick up levels. Uncomplicated operation
leads to lower costs for labor. ●
Figure 2. The narrow nip on conventionalrod surface sizing equipment means highspecific pressure at the metering point.Foreign particles in low-grade base paperand sizing starch would collect at themetering point. Therefore, more expen-sive base paper and sizing starch have tobe used with this equipment.
22 UMV HEADLINES
N either method is repulpable, and
therefore not sustainable.Michelman water-based coatings
are not only repulpable, but also safer to
apply and conserve production resources.
Water-based barrier coatings are ap-
plied to paper in order to provide a barrier
between the paper and the environment
around it.
Many applications call for a barrier tobe applied to a liner, corrugated sheet, or
carton board. These barriers are used to
protect the packaging contents from expo-
sure to external forces, such as water or
humidity. Protection from these forces also
helps to maintain the strength and integrity
of the package.
There are many benefits for using
water-based coatings which can be recycledover and over again.
• Sustainability of our natural resources• Cost effective• Repulpable• Printable• Strong• Food contact compliant
In addition to providing barrier, coatings
can be applied to provide other forms of
functionality. This functionality can be in
the form of corrosion or anti-static protec-
tion for the item to be packaged, abrasion
resistance for the prevention of damage to
contents by scuffing, or release for pack-
aged food and bakery products.Coatings can also be applied to the
outside of the package to control the slip
properties. Many of the Michelman barrier
coatings are Bfr, EU and FDA compliant
meeting the International Standards forfood contact.
There are a number of application
methods that are available for water-based
coatings. They can be applied using a blade,
rod, or roll coater in-line on a corrugator or
other converting equipment. In some cases,
a flexo can be used to provide limited bar-
rier and functionality. Where both sidesneed to be coated, the UMV Mirroblade
has proven to be an ideal applicator.
Mirroblade barrier coats efficientlyWith the Mirroblade concept, paper and
board can be blade coated on both sides si-
multaneously in a single space that is less
than one-third the size of most two-station
layout. And because the Mirroblade coaterhas no drives the difficulties of motor and
gearbox placement are eliminated and the
coater can be placed almost anywhere.
Recent successful trials have shown
topside applications to provide the outer
print surface with the characteristics needed
by the client. Brightness a-nd printability of
the highest standards can be achieved, fac-tors that must also be attained while adding
the barrier coating on the backside.
This must also be achieved while add-
ing the barrier coating on the backside.
Michelman coatings provide a barrier
against Water, Oil and Grease (KIT Value),
and Moisture Vapour under temperate
conditions (MVTR) and can all be applied
using the Mirroblade. Work done recentlyon cartons targeted for the pet-food and
domestic packaging markets have met the
severe testing criteria required.
This will enable the clients to choose a
packaging system that avoids the use ofpolyethylene, and the use of unwanted
chemicals, such as Fluorine.
The resulting packages not only pro-
vide barrier properties, but also allow for
the packaging to be recyclable and repulp-
able; where it would not have been using
other alternatives. Such packages can be
used for grease protection in pizza boxes,fast food, pet and animal foods, moisture
protection for detergents and other foods,
and water protection for the packaging of
fruit, vegetables, plants and flowers.
Michelman is a global manufacturer of per-
formance-enhancing barrier, functional, and
decorative coatings for flexible film packag-
ing, paperboard, and corrugated boxes.
Two strong companiesUMV Machinery has over 40 years
experience in rebuilding various types of
paper machines for customers all over the
world. By bringing these two strongly estab-
lished companies together there is every
possibility to use this technology anywhere
in the world where coating is required onboth sides of a substrate.
Coating trends today are about
efficient uses of packaging and eliminating
excess waste to our landfills. With an under-
standing of the supply chain, production
process, market and end user needs, Michel-
man partners with customers to uncover
new ways to add value to their products. ●
Christopher CoyneMichelman International & Co SNC
Repulpable barriercoatings and the MirrobladeIn today’s packaging world, the demand for sustainability inpackaging calls for safer, more environmentally acceptable barriertreatment methods. Polyethylene lamination or extrusion commonly provides barrier protection in Europe, while wax cascading or curtain coating is used in North America.
UMV HEADLINES 23
A fter the fusion of the Jefferson
Smurfit Group and Kappa Pack-
aging to form the Smurfit Kappa
group, the activities of the two boxboard
manufacturers, Baden Karton and Hoya
Karton, and the converter, Baden Packag-
ing, were united under the Smurfit KappaCarton subdivision.
According to Wolfgang Suerbaum,
CEO of the Smurfit Kappa Carton Subdi-
vision, and Armin Buschmann, CEO of
Hoya, this is an ideal constellation: Baden
Karton with an annual production of
150,000 tpy and Hoya Karton with
85,000 tpy – two strong boxboard manu-
facturers coupled with a competent con-verter form an excellent base for innova-
tive product development.
Carton packaging for foodstuffs, pet
foods, detergents and cleaning materials
have to be coated with a barrier to protect
the contents from moisture and the pack-
aging from fat and oil. In key European
countries the demand for packaging with
barrier characteristics is about 600,000 tpy
and rising.
Until now, protective barriers have
been a hazard to both health and the envi-
ronment, due to the use of Per Fluorinated
Tensides or PFT chemicals or polyethylene
coatings for the boxboard finishing. Theuse of or PFT compounds is especially
problematic.
The tensides problemPFTs are artificially produced fluorinated
carbon compounds. They are extraordinar-
ily chemical resistant and this, plus their
unique surface tension characteristics,
make PFTs useful in the paper and cartonindustries.
PFTs make cartons resistant to fat, oil
and water. However, because they contain
per fluoric octanoic acid or PFOA, they
have a high degree of toxicity for humans
and animals, which, according to Green-
peace, is comparable to the toxicity of
DDT (Dichlorodiphenyltrichloroethane).
Hoya Karton in Hoya, Germany, installed the first-ever folding boxboardcoating line utilizing Mirroblade technology. Until then, this technology wasused for producing high-quality printing and writing papers. Mirroblade iscompact, has neither motors nor gears, can be precisely controlled, while andsimultaneously coating the front and back of boxboard.
PFTs build up in the organs and in
the blood, are not biodegradable and aresuspected of compromising fertility and
being carcinogenic. Consequently, the
European Parliament issued an EU-wide
ban on the use of PFOS on 25 October
2006. PFOA is on the watch list.
A challenge and opportunityfor Smurfit KappaAccordingly, Smurfit Kappa Carton, morespecifically, Hoya Karton began develop-
ing environmentally friendly protective
barriers free of PFTs in 2005.
In the autumn of 2006 the develop-
ment team reported, ”Mission complete”
and presented a innovative technology for
environmentally friendly coating of fold-
ing boxboard – a process that was alsoconvincing economically and thereby
gained the approval of management dur-
ing the same year.
The new protective barrier is free of
PFTs, is recyclable and biodegradable and
meets the requirements of the XXXVI (36)
Recommendation of the Federal Institute
for Risk Assessment in Germany and the
Federal Food and Drug Administration inthe USA.
When combined with Hoya Karton’s
excellent stiffness, surface and printability
properties, Mirroblade Technology gives
Smurfit Kappa Carton access to new
customers and markets.
Installing the new Mirroblade
technology, and the introduction of a newenvironmentally friendly protective barrier
sets new standards for the packaging
industry. ●
Hoya Karton sets newstandards for protective barriers
Armin Buschmann, CEO Hoya, left, and Wolfgang Suerbaum, CEO SmurfitKappa Carton, pushed the investment in Mirroblade and new protectivebarrier technology through in record time.
24 UMV HEADLINES
UMV Pulp and PaperPO Box 162SE-661 24 Säffle, SwedenTel.: +46 522 982 80Fax: +46 522 983 23E-mail: info@umv.mattsson.seWebsite: www.umv.mattsson.se
Publisher: Louise Törnefalk Svanqvist,President, UMV Pulp and Paper
Material in Headlines may be reprod-uced with permission of the publisher.Opinions expressed in this publicationare those of the authors or personsinterviewed and do not necessarilyreflect the views of the publisher orUMV.
Editorial services: David WoldEnglish Language Services AB
Cover photo: Kurt Johansson
Design: Bernhard Zirn
Printing: AB Åmålstryck, Åmål, Sweden
SERVICE AGREEMENTS:
Boost coater availabilityand enhance productivity“The purpose of our service contracts is to ensure availability, performance and productivity on UMV machines,” says KentÅström, service manager at UMV Pulp & Paper.
Typically service include two yearly overhaul
visits. A service technician and/or an electrician
carry them out over a period of about two days
during a mill’s scheduled maintenance stop-
pages.The first overhaul visit includes following
an extensive inspection checklist to determine
the overall status of the machinery as well as
conducting tests and reviewing the basic set-
tings of the coating machinery. If necessary,
other work is carried out during the visit.
The second overhaul visit often involves
overhauling the machinery to correct any prob-lems identified during the first visit.
Visits also include conducting an inven-
tory of spare parts to determine what might be
necessary to buy. UMV and mill staffs meet
during the visit to review innovations and new
developments in the area of coating technology.
“Training and updating operators and
maintenance people has proven to be one of
the more important aspects of the overhaul
visit. It’s perfectly natural for seasoned opera-
tors to establish routines that require a bit ofadjusting. New operators also benefit from
training,” says Mr. Åström. Finally, reports and
test records from the service visits are written
and submitted to the mill.
Apart from ensuring smooth operation,
service contracts offer mills other benefits such
as special discount on labor and on all spare
parts. Additional service visits and/or work out-side the service agreement are charged sepa-
rately and according to the UMV standard
price list, but also with a discount list.
Customers with service agreements are also
granted priority in case of emergency calls. ●
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