Operational Excellence Success Story
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1 Operational Excellence Success Story PMT The right Shoe Press Valter Canelli PaperCon 2011 Page 1552
2 Mill Overview Pap. De Clairefontaine #5 Fine Paper Wire 148 in Speed 1970fpm 630 pli 400 pli PaperCon 2011 Page 1553
3 Production Overview before Reel speed Thickness g/m 2 ft/min mils Laser print Notebooks ? Copy color Envelope Envelope Offset ? New grade 270 na na PaperCon 2011 Page 1554
4 Mill Targets before Reel speed Thickness g/m 2 ft/min mils Laser print Notebooks ? Copy color Envelope Envelope Offset ? New grade 270 na na Production Smoothness Two sidedness Bulk Flexibility PaperCon 2011 Page 1555
5 Problem Description To justify a Shoe Press Investment PaperCon 2011 Page 1556
6 Problem Description Main Paper Properties PROFILES STRENGTH PROPERTIES PRINTING PROPERTIES DIMENSIONAL PROPERTIES CD BASIS WEIGHT MD/CD RATIO FORMATION STABILITY MD BASIS WEIGHT SCT, RCT SMOOTHNESS CURL CD MOISTURE BURST SURFACE STRENGTH SHRINKAGE MD MOISTURE CONCORA (CMT) INK ABSORPTION BULK / DENSITY FIBER ORIENTATION Z - STRENGTH GLOSS CALIPER CALIPER STIFFNESS POROSITY COCKLING INTERNAL BONDING BRIGHTNESS OPACITY SHEET SYMMETRY PaperCon 2011 Page 1557
7 Problem Description PRESS INFLUENCE Main Paper Properties PROFILES STRENGTH PROPERTIES PRINTING PROPERTIES DIMENSIONAL PROPERTIES CD BASIS WEIGHT MD/CD RATIO FORMATION STABILITY MD BASIS WEIGHT SCT, RCT SMOOTHNESS CURL CD MOISTURE BURST SURFACE STRENGTH SHRINKAGE MD MOISTURE CONCORA (CMT) INK ABSORPTION BULK / DENSITY FIBER ORIENTATION Z - STRENGTH GLOSS CALIPER CALIPER STIFFNESS POROSITY COCKLING INTERNAL BONDING BRIGHTNESS OPACITY SHEET SYMMETRY PaperCon 2011 Page 1558
8 Problem Description Important for NOT-printed Packaging Grades Main Paper Properties PROFILES STRENGTH PROPERTIES PRINTING PROPERTIES DIMENSIONAL PROPERTIES CD BASIS WEIGHT MD/CD RATIO FORMATION STABILITY MD BASIS WEIGHT SCT, RCT SMOOTHNESS CURL CD MOISTURE BURST SURFACE STRENGTH SHRINKAGE MD MOISTURE CONCORA (CMT) INK ABSORPTION BULK / DENSITY FIBER ORIENTATION Z - STRENGTH GLOSS CALIPER CALIPER STIFFNESS POROSITY COCKLING INTERNAL BONDING BRIGHTNESS OPACITY SHEET SYMMETRY PaperCon 2011 Page 1559
9 Problem Description Important for Writing & Printing Grades Main Paper Properties PROFILES STRENGTH PROPERTIES PRINTING PROPERTIES DIMENSIONAL PROPERTIES CD BASIS WEIGHT MD/CD RATIO FORMATION STABILITY MD BASIS WEIGHT SCT, RCT SMOOTHNESS CURL CD MOISTURE BURST SURFACE STRENGTH SHRINKAGE MD MOISTURE CONCORA (CMT) INK ABSORPTION BULK / DENSITY FIBER ORIENTATION Z - STRENGTH GLOSS CALIPER CALIPER STIFFNESS POROSITY COCKLING INTERNAL BONDING BRIGHTNESS OPACITY SHEET SYMMETRY PaperCon 2011 Page 1560
10 Problem Description General Shoe Press Advantages: + Dryness + Bulk + Paper Strength PaperCon 2011 Page 1561
11 Problem Description Shoe Press Issues: Investment Cost (ROI) Impact on Paper Quality PaperCon 2011 Page 1562
12 Problem Description Why is it difficult to justify the Shoe Press investment?: Weight Issues Existing Crane Limits Building Loads Limits Dimensions Issues CD Interchange ability Diameter Rebuild Down Time PaperCon 2011 Page 1563
13 Problem Description Why is it difficult to justify the Shoe Press investment?: Felt Marking Issue Roughness Two-Sidedness Issue PaperCon 2011 Page 1564
14 Solution Strategy Long NIP Residence Time +++ Felt Marking NIP Specific Pressure + Felt Marking A Shoe Press with a Shorter Shoe PaperCon 2011 Page 1565
15 Solution Strategy Machine Direction NIP Profile Speci ific pressure e (MPa) Nip Length (mm) 250 mm shoe PaperCon 2011 Page 1566
16 Solution Strategy Machine Direction NIP Profile Speci ific pressure e (MPa) Nip Length (mm) 250 mm shoe Dryness PaperCon 2011 Page 1567
17 Solution Strategy Machine Direction NIP Profile Speci ific pressure e (MPa) Nip Length (mm) 250 mm shoe Dryness Marking PaperCon 2011 Page 1568
18 Solution Strategy Machine Direction NIP Profile ic pressur re (MPa) Specif Nip Length (mm) 250 mm shoe Dryness Marking PaperCon 2011 Page 1569
19 Solution Strategy Machine Direction NIP Profile Specifi ic pressure e (MPa) Nip Length (mm) 250 mm shoe Dryness Marking PaperCon 2011 Page 1570
20 Solution Strategy Machine Direction NIP Profile Specif fic pressu re (MPa) Dryness loss Nip Length (mm) 250 mm shoe Dryness Marking PaperCon 2011 Page 1571
21 Solution Strategy Machine Direction NIP Profile re (MPa) Specif fic pressu Felt marking reduction Nip Length (mm) 250 mm shoe Dryness Marking PaperCon 2011 Page 1572
22 Solution Strategy Machine Direction NIP Profile fic pressu ure (MPa) Speci Nip Length (mm) 250 mm shoe Dryness Marking 125 mm shoe PaperCon 2011 Page 1573
23 Solution Strategy Long NIP Residence Time +++ Felt Marking NIP Specific Pressure + Felt Marking A Shoe Press with a Shorter Shoe With a shorter shoe we can achieve same specific pressure at a lower total NIP Lower total NIP makes the shoe press lighter A lighter shoe press reduces the total investment cost PaperCon 2011 Page 1574
24 Solution Strategy PaperCon 2011 Page 1575
25 Implementation Pilot Hand Sheet Trials Wet Sample PaperCon 2011 Page 1576
26 Implementation Pilot Hand Sheet Trials 0,66 0,64 3 points at same density 2 points at same density ensity [g/c cc] D 0,62 0,6 0,58 0,56 0,54 0, Dryness [%] Roll Press Smarnip STD Shoe Press Smarnip Roll Press STD Shoe Press PaperCon 2011 Page 1577
27 Implementation before 630 pli 400 pli PaperCon 2011 Page 1578
28 Implementation after 1030 pli 400 pli SMARNIP US patent PaperCon 2011 Page 1579
29 Success before Reel speed Thickness g/m 2 ft/min mils Laser print Notebooks ? Copy color Envelope Envelope Offset ? New grade 270 na na PaperCon 2011 Page 1580
30 Success Reel speed before after Average Thickness Reel speed Thickness production increase (1 year) g/m 2 ft/min mils ft/min mils % Laser print Notebooks ? 1765 = 7.5 Copy color Envelope Envelope Offset ? 690 = 0 New grade 270 na na 145? Na Total average production increase (1 year): 7.5% more Steam consumption: 6% less PaperCon 2011 Page 1581
31 Success Reel speed before after Average production increase Thickness Reel speed Thickness (1 year) g/m 2 ft/min mils ft/min mils % Laser print Notebooks ? 1765 = 7.5 Copy color Envelope Envelope Offset ? 690 = 0 New grade 270 na na 145? Na Total average production increase (1 year): 7.5% more Steam consumption: 6% less PaperCon 2011 Page 1582
32 Success + 10% Production increase - 6% Steam Consumption + Bulk + Flexibility PaperCon 2011 Page 1583
33 Success Blanket Life Average speed 1640fpm Average NIP 800pli Blanket number Days on machine Millions Nip cycles Reason for removal Annual shut down PaperCon 2011 Page 1584
34 Success Blanket Life Average speed 1640fpm Average NIP 800pli Blanket number Days on machine Millions Nip cycles Reason for removal Annual shut down PaperCon 2011 Page 1585
35 Mill Overview Pap. De Clairefontaine #6 Fine Paper Wire 158 in Speed 3610fpm PaperCon 2011 Page 1586
36 Implementation 1710 pli PaperCon 2011 Page 1587
37 Success + 20% Speed increase + Smoothness + Bulk 2.5% less raw material for same paper caliper PaperCon 2011 Page 1588
38 Success PaperCon 2011 Page 1589
39 Success Sizes: in PaperCon 2011 Page 1590
40 Features It is a roll with the shoe press features Longer nip profile (more dewatering) Better MD nip profile (gentle - no rewetting) Flexibility (no crown issues) Better moisture CD profile It is a shoe press with less negative points Possibility to simulate a roll nip Interchangeable with a roll Less space required (reuse of frame) Lighter (no issues with crane, building, ) Longer blanket life PaperCon 2011 Page 1591
41 Conclusion 1980 Standard shoe press has been originally designed (by Beloit) for Board applications, targeting dryness and densification 1994 first Shoe Press application on Fine Paper, without adapting the concept 2003 PMT patented the SMARNIP (US patent ) for bulk sensitive grades (Fine Paper, Board, Sack Kraft ) 2011 The SMARNIP is a proven product (14) references On different grades In Europe and Asia PaperCon 2011 Page 1592
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