Leading paper manufacturers rely on Voith expertise for resource-efficient rebuilds and optimization projects to boost competitiveness

With its full-line supplier approach, Voith Paper strengthens position as partner of choice for extensive rebuilds and customized optimization projects. Shifting consumer demands, tougher environmental regulations and ongoing supply chain issues with raw materials have combined to create a perfect storm in the paper industry. To remain competitive in unprecedented conditions, leading papermakers around the globe are relying on Voith to modernize their existing paper production lines, undertake comprehensive grade conversions or upgrade their current assets in the market. As a full-line supplier, Voith realizes every type of rebuild to give paper machines a second life. In the process, Voith expertise, innovative components and advanced digital tools ensure customers achieve their efficiency and productivity targets with a lower capital investment.

Extensive grade conversion in Indonesia
In September 2021, Voith kicked off the grade conversion of Mojokerto MSE-PM2 for PT Mega Surya Eratama. The extensive rebuild will transform the former newsprint paper machine, which is currently out of service, to a state-of-the-art packaging production line at the company’s Mojokerto paper mill in East Java, Indonesia.

As is the case with every rebuild, Voith is placing a special focus on high machine availability, technological efficiency, process stability and sustainability with the lowest possible energy balance for the plant. After conversion, the PM 2 will produce high-quality containerboard grades between 70 g/m2 and 180 g/m2, with a design speed of 1,400 m/min and 6,660 mm paper width at reel. After start-up, the XcelLine paper machine will have an annual production capacity of 450,000 tons, and, as a result, the PM 2 will be one of the most powerful paper machines of this grade in Indonesia. The Voith scope of supply includes a forming section rebuild into a DuoFormer CBh with shoe-blade technology, a new DuoCentri NipcoFlex Press and SpeedSizer AT film sizer for starch application. The order also includes a complete BlueLine stock preparation and approach flow line. The start-up after conversion is scheduled for the end of 2023.

“We were convinced by Voith’s capability as a full-line supplier to meet our highest benchmark and sustainability requirements for this strategic grade conversion,” says Eric Saputra, General Manager at PT Mega Surya Eratama. “Given their extensive experience and innovative equipment, Voith is ideally positioned to bring out the full potential of the PM 2 production line. We rely on Voith to support us in producing the highest paper quality on a machine with the best operational reliability.”

Record-breaking 30th shoe press rebuild
This year, Voith marked the 30th successful rapid shoe press rebuild in a row in China, with five more underway. The most recent was completed for the Sun Paper Group. As it took a mere seven days from shutdown to paper on reel, the project set a record for the fastest shoe press rebuild in the region, saving the customer valuable production time as a result. The centerpiece is a new NipcoFlex shoe press for the existing press section. In addition, the scope of delivery included a PLC control system for NFP, erection and start-up service as well as spare part and wear part packages. Previously, in December 2020, Voith successfully completed the rebuild and smooth start-up of the NipcoFlex shoe press on PM 9 for JiangXi WuXing, a leading paper manufacturer based in Jiujiang City.

Large-scale Voith rebuilds spread across the globe
Voith successfully provides full-line supplier support for large-scale rebuilds around the world, all of which have ambitious efficiency targets and productivity goals. In Spain, for instance, PAPRESA, the leading southern European manufacturer of newsprint, commissioned Voith for the resource-efficient grade conversion of PM 5 from newsprint paper to testliner and corrugating medium at the company’s Rentería mill. Papermaking 4.0 tools supports the company’s ambitious efficiency and sustainability goals. Other notable projects in Europe include the PM 2 rebuild for Schumacher Packaging, a corrugated board producer and full-range supplier of paper-based packaging solutions. The rebuild at the company’s Myszków site in Poland involves a forming section upgrade to DuoFormer D, a new headbox MasterJet Pro and DuoShake DG 800, which will ensure the necessary dewatering capacity and final paper quality. While in North America, Domtar, a leading U.S. paper manufacturer, has entrusted Voith to support the company’s entry into the containerboard market and set higher industry standards. At the company’s Kingsport mill in Tennessee, Voith is to install a BlueLine stock preparation line and perform the grade conversion of its production line.

“Drawing on our full-line supplier expertise, we provide the know-how and technology for rebuilds of every kind. Whatever the ultimate business and sustainability goals of an optimization project, our comprehensive approach ensures we are in a leading position to fully exploit the potential of existing paper production lines,” states Martin Jauch, Senior Vice President Global Rebuilds at Voith.