Operational Excellence Success Story PMT The right Shoe Press Valter Canelli PaperCon 2011 Page 1552
Mill Overview Pap. De Clairefontaine #5 Fine Paper Wire 148 in Speed 1970fpm 630 pli 400 pli PaperCon 2011 Page 1553
Production Overview before Reel speed Thickness g/m 2 ft/min mils Laser print 100 1475 4.1 Notebooks 90 1640? Copy color 80 1675 4.3 Envelope 90 1525 4.8 Envelope 120 1245 6.3-6.6 Offset 200 690? New grade 270 na na PaperCon 2011 Page 1554
Mill Targets before Reel speed Thickness g/m 2 ft/min mils Laser print 100 1475 4.1 Notebooks 90 1640? Copy color 80 1675 4.3 Envelope 90 1525 4.8 Envelope 120 1245 6.3-6.6 Offset 200 690? New grade 270 na na Production Smoothness Two sidedness Bulk Flexibility PaperCon 2011 Page 1555
Problem Description To justify a Shoe Press Investment PaperCon 2011 Page 1556
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
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
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
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
Problem Description General Shoe Press Advantages: + Dryness + Bulk + Paper Strength PaperCon 2011 Page 1561
Problem Description Shoe Press Issues: Investment Cost (ROI) Impact on Paper Quality PaperCon 2011 Page 1562
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
Problem Description Why is it difficult to justify the Shoe Press investment?: Felt Marking Issue Roughness Two-Sidedness Issue PaperCon 2011 Page 1564
Solution Strategy Long NIP Residence Time +++ Felt Marking NIP Specific Pressure + Felt Marking A Shoe Press with a Shorter Shoe PaperCon 2011 Page 1565
Solution Strategy Machine Direction NIP Profile Speci ific pressure e (MPa) 16 14 12 10 8 6 4 2 0 0 50 100 150 200 250 300 350 Nip Length (mm) 250 mm shoe PaperCon 2011 Page 1566
Solution Strategy Machine Direction NIP Profile Speci ific pressure e (MPa) 16 14 12 10 8 6 4 2 0 0 50 100 150 200 250 300 350 Nip Length (mm) 250 mm shoe Dryness PaperCon 2011 Page 1567
Solution Strategy Machine Direction NIP Profile Speci ific pressure e (MPa) 16 14 12 10 8 6 4 2 0 0 50 100 150 200 250 300 350 Nip Length (mm) 250 mm shoe Dryness Marking PaperCon 2011 Page 1568
Solution Strategy Machine Direction NIP Profile ic pressur re (MPa) Specif 16 14 12 10 8 6 4 2 0 0 50 100 150 200 250 300 350 Nip Length (mm) 250 mm shoe Dryness Marking PaperCon 2011 Page 1569
Solution Strategy Machine Direction NIP Profile Specifi ic pressure e (MPa) 16 14 12 10 8 6 4 2 0 0 50 100 150 200 250 300 350 Nip Length (mm) 250 mm shoe Dryness Marking PaperCon 2011 Page 1570
Solution Strategy Machine Direction NIP Profile Specif fic pressu re (MPa) 16 14 12 10 8 6 4 2 0 Dryness loss 0 50 100 150 200 250 300 350 Nip Length (mm) 250 mm shoe Dryness Marking PaperCon 2011 Page 1571
Solution Strategy Machine Direction NIP Profile re (MPa) Specif fic pressu 16 14 12 10 8 6 4 2 0 Felt marking reduction 0 50 100 150 200 250 300 350 Nip Length (mm) 250 mm shoe Dryness Marking PaperCon 2011 Page 1572
Solution Strategy Machine Direction NIP Profile fic pressu ure (MPa) Speci 16 14 12 10 8 6 4 2 0 0 50 100 150 200 250 300 350 Nip Length (mm) 250 mm shoe Dryness Marking 125 mm shoe PaperCon 2011 Page 1573
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
Solution Strategy PaperCon 2011 Page 1575
Implementation Pilot Hand Sheet Trials Wet Sample PaperCon 2011 Page 1576
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 0,52 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 Dryness [%] Roll Press Smarnip STD Shoe Press Smarnip Roll Press STD Shoe Press PaperCon 2011 Page 1577
Implementation before 630 pli 400 pli PaperCon 2011 Page 1578
Implementation after 1030 pli 400 pli SMARNIP US patent 7811419 PaperCon 2011 Page 1579
Success before Reel speed Thickness g/m 2 ft/min mils Laser print 100 1475 4.1 Notebooks 90 1640? Copy color 80 1675 4.3 Envelope 90 1525 4.8 Envelope 120 1245 6.3-6.6 Offset 200 690? New grade 270 na na PaperCon 2011 Page 1580
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 100 1475 4.1 1581 4.2 7.0 Notebooks 90 1640? 1765 = 7.5 Copy color 80 1675 4.3 1840 4.1 4.6 10.0 Envelope 90 1525 4.8 1555 4.9 2.0 Envelope 120 1245 6.3-6.6 1309 6.6 6.8 5.0 Offset 200 690? 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
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 100 1475 4.1 1581 4.2 7.0 Notebooks 90 1640? 1765 = 7.5 Copy color 80 1675 4.3 1840 4.1 4.6 10.0 Envelope 90 1525 4.8 1555 4.9 2.0 Envelope 120 1245 6.3-6.6 1309 6.6 6.8 5.0 Offset 200 690? 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
Success + 10% Production increase - 6% Steam Consumption + Bulk + Flexibility PaperCon 2011 Page 1583
Success Blanket Life Average speed 1640fpm Average NIP 800pli Blanket number Days on machine Millions Nip cycles Reason for removal 1 706 207 Annual shut down PaperCon 2011 Page 1584
Success Blanket Life Average speed 1640fpm Average NIP 800pli Blanket number Days on machine Millions Nip cycles Reason for removal 1 706 207 Annual shut down PaperCon 2011 Page 1585
Mill Overview Pap. De Clairefontaine #6 Fine Paper Wire 158 in Speed 3610fpm PaperCon 2011 Page 1586
Implementation 1710 pli PaperCon 2011 Page 1587
Success + 20% Speed increase + Smoothness + Bulk 2.5% less raw material for same paper caliper PaperCon 2011 Page 1588
Success PaperCon 2011 Page 1589
Success Sizes: 28 30 44 in PaperCon 2011 Page 1590
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
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 7811419) 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