operational excellence sstsuccess story - tappi ppt.pdf · operational excellence sstsuccess story...

Operational ExcellenceS StSuccess Story

PMT“The right Shoe Press”

Valter Canelli

PaperCon 2011 552

• Fine Paper• Wire 148 inMill Overview• Speed 1970fpm

• Pap. De Clairefontaine #5

630 pli 400 pli

PaperCon 2011 Page 1553

Production Overview

before

Reel speed

Thickness

g/m2 ft/min mils

Laser print 100 1475 4.1

Notebooks 90 1640 ?

Copy color 80 1675 4.3Copy 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


Mill Targets

before

ProductionSmoothness

Reel speed

Thickness

g/m2 ft/min milsSmoothnessTwo sidednessBulk


Notebooks 90 1640 ?

Copy color 80 1675 4.3Flexibility

Copy color 80 1675 4.3


Envelope 120 1245 6.3 - 6.6

Offset 200 690 ?

New grade 270 na na


Problem Description

• To justify a Shoe Press InvestmentTo justify a Shoe Press Investment


Problem Description

• Main Paper Properties

PROFILES STRENGTHPROPERTIES

PRINTING PROPERTIES

DIMENSIONAL PROPERTIES

CD BASIS WEIGHT STABILITYMD/CD RATIO FORMATION

MD BASIS WEIGHT

CD MOISTURE

CURL

SHRINKAGE

SCT , RCT

BURST

SMOOTHNESS

SURFACE STRENGTH

MD MOISTURE

FIBER ORIENTATION

CALIPER

BULK / DENSITY

CALIPER

COCKLING

CONCORA (CMT)

Z - STRENGTH

STIFFNESS

INK ABSORPTION

GLOSS

POROSITY

INTERNAL BONDING BRIGHTNESS

OPACITY

SHEET SYMMETRY


Problem DescriptionPRESS INFLUENCE



PRINTING PROPERTIES



MD BASIS WEIGHT

CD MOISTURE

CURL

SHRINKAGE

SCT , RCT

BURST

SMOOTHNESS

SURFACE STRENGTH

MD MOISTURE

FIBER ORIENTATION

CALIPER

BULK / DENSITY

CALIPER

COCKLING

CONCORA (CMT)

Z - STRENGTH

STIFFNESS

INK ABSORPTION

GLOSS

POROSITY


OPACITY

SHEET SYMMETRY


Problem Description


Important for NOT-printed Packaging Grades


PRINTING PROPERTIES



MD BASIS WEIGHT

CD MOISTURE

CURL

SHRINKAGE

SCT , RCT

BURST

SMOOTHNESS

SURFACE STRENGTH

MD MOISTURE

FIBER ORIENTATION

CALIPER

BULK / DENSITY

CALIPER

COCKLING

CONCORA (CMT)

Z - STRENGTH

STIFFNESS

INK ABSORPTION

GLOSS

POROSITY


OPACITY

SHEET SYMMETRY


Problem Description


Important for Writing & Printing Grades


PRINTING PROPERTIES



MD BASIS WEIGHT

CD MOISTURE

CURL

SHRINKAGE

SCT , RCT

BURST

SMOOTHNESS

SURFACE STRENGTH

MD MOISTURE

FIBER ORIENTATION

CALIPER

BULK / DENSITY

CALIPER

COCKLING

CONCORA (CMT)

Z - STRENGTH

STIFFNESS

INK ABSORPTION

GLOSS

POROSITY


OPACITY

SHEET SYMMETRY


Problem Description

• General Shoe Press Advantages:

+ Dryness

+ Bulk

+ Paper Strength+ Paper Strength


Problem Description

• Shoe Press Issues:

Investment Cost (ROI)

Impact on Paper Quality


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


Problem Description

• Why is it difficult to justify the Shoe Press investment?:

Felt Marking Issue

Roughness Two-Sidedness Issue


Solution Strategy

Long NIP Residence Time +++ Felt MarkingNIP Specific Pressure + Felt MarkingNIP Specific Pressure + Felt Marking

A Shoe Press with a Shorter Shoe


Solution Strategy

16

• Machine Direction NIP Profile

10

12

14

e (M

Pa)

6

8

10

ific

pres

sure

0

2

4

Spec

i

0 50 100 150 200 250 300 350Nip Length (mm)

250 mm shoe

PaperCon 2011 66

Solution Strategy

16


10

12

14

e (M

Pa)

6

8

10

ific

pres

sure

0

2

4

Spec

i

0 50 100 150 200 250 300 350Nip Length (mm)

250 mm shoe Dryness


Solution Strategy

16


10

12

14

e (M

Pa)

6

8

10

ific

pres

sure

0

2

4

Spec

i

0 50 100 150 200 250 300 350Nip Length (mm)

250 mm shoe Dryness Marking


Solution Strategy

16


101214

re (M

Pa)

468

10

ic p

ress

ur

024

Spec

if

0 50 100 150 200 250 300 350Nip Length (mm)



Solution Strategy

16


101214

e (M

Pa)

68

10

ic p

ress

ure

024

Spec

ifi

0 50 100 150 200 250 300 350Nip Length (mm)



Solution Strategy

16• Machine Direction NIP Profile

101214

re (M

Pa)

468

10

fic p

ress

u

Dryness loss

024

Spec

if y

0 50 100 150 200 250 300 350Nip Length (mm)



Solution Strategy

16Felt marking reduction• Machine Direction NIP Profile

101214

re (M

Pa)

468

fic p

ress

u

024

Spec

if

0 50 100 150 200 250 300 350Nip Length (mm)



Solution Strategy

16• Machine Direction NIP Profile

101214

ure

(MPa

)

468

fic p

ress

u

024

0 50 100 150 200 250 300 350

Spec

i

0 50 100 150 200 250 300 350Nip Length (mm)

250 mm shoe Dryness Marking 125 mm shoe


Solution Strategy

Long NIP Residence Time +++ Felt MarkingNIP Specific Pressure + Felt MarkingNIP 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 NIPtotal NIPLower total NIP makes the shoe press lighterA lighter shoe press reduces the total investment cost


Solution Strategy


Implementation

• Pilot Hand Sheet Trials

Wet Sample


Implementation

0,66

• Pilot Hand Sheet Trials

3 points at same density

0,62

0,64

cc]

2 points at same density 3 points at same density

0,58

0,6

ensi

ty [g

/c

0,54

0,56D

0,5235 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51

Dryness [%]

Roll Press Smarnip STD Shoe PressSmarnip Roll Press STD Shoe Press


Implementation

• before

630 pli 400 pli


Implementation

• after

1030 pli 400 pli

SMARNIP® US patent 7811419


Success

before

Reel speed

Thickness

g/m2 ft/min mils


Notebooks 90 1640 ?

Copy color 80 1675 4.3Copy color 80 1675 4.3


Envelope 120 1245 6.3 - 6.6

Offset 200 690 ?

New grade 270 na na


Success

before after Averageproduction increaseincrease(1 year)Reel

speedThickness Reel

speedThickness

g/m2 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 10.0Copy 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% moreg p ( y )

Steam consumption: 6% less


Success

before after Averageproduction

increase(1 year)Reel

speedThickness Reel

speedThickness

g/m2 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 10.0Copy 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% moreg p ( y )

Steam consumption: 6% less


Success

+ 10% Production increase

- 6% Steam Consumptionp

+ Bulk

+ Flexibility


Success

• Blanket LifeA d 1640fAverage speed 1640fpmAverage NIP 800pli

Blanket number Days on machine

MillionsNip cycles

Reason for removalp y

1 706 207 Annual shut1 706 207 Annual shut down


• Fine Paper• Wire 158 inMill Overview• Speed 3610fpm

• Pap. De Clairefontaine #6


Implementation

1710 pli


Success

+ 20% Speed increase

+ Smoothness

+ Bulk 2.5% less raw material for same paper caliper


Success


Success

• Sizes: 28 – 30 – 44 in


Features

It is a roll with the shoe press featuresIt 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 ) Lighter (no issues with crane, building,…) Longer blanket life


Conclusion

1980 Standard shoe press has been originally designed (byBeloit) for Board applications, targeting dryness anddensification

1994 first Shoe Press application on Fine Paper without adapting 1994 first Shoe Press application on Fine Paper, without adaptingthe concept

2003 PMT patented the SMARNIP® (US patent 7811419) for bulkiti d (Fi P B d S k K ft )sensitive grades (Fine Paper, Board, Sack Kraft…)

2011 The SMARNIP® is a proven product (14) references (14) references On different grades In Europe and Asia


operational excellence sstsuccess story - tappi ppt.pdf · operational excellence sstsuccess story...

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