METSO’S CUSTOMER MAGAZINE FOR THE PULP AND PAPER INDUSTRY pptx

No. 2/2010METSO’S CUSTOMER MAGAZINE FOR THE PULP AND PAPER INDUSTRY
results
pulp & paper
SCA Packaging Munksund
White liquor quality and capacity up
thanks to cutting-edge technology 12
‘Game-changing’ multilayer
curtain coating technology
– Are you ready?  15
Mondi S
´
wiecie ECO7
- Economy meets ecology  18
Metso and Tamfelt
join together
- A perfect union formed
for the customers 8
2 /    
Dear reader,
Even though the global recession has slowed down business, it has not put a brake on our efforts to develop new
technology.
Early in the year we kicked off a multi-year project together with Stora Enso and Domtar (DMS) to develop a pulp
mill biorefinery of the future, utilizing new pulp technology. We’re aiming at a process with better energy and cost
efficiency, lower capital investment costs and a more economical use of fiber. We believe we can achieve all of these
goals without compromising on the pulp properties required for excellent paper or board - in fact, just the contrary!
The technology being developed will provide better opportunities to produce new wood-based biocompounds.
The new DMS project will offer exciting new possibilities for a breakthrough in sustainable chemical pulp produc-
tion. As such, it accords with the strategic RTD objectives set for the Finnish, Swedish and North American forest
clusters.
We are focusing another major effort on rebuilding the pilot paper machines at our Jyväskylä Paper Technology
Center. Now we will be able to provide, even more flexibly than before, pilot trial possibilities that are at the cutting

edge of global development - including ground-breaking paper making technology that will afford our customers
superb opportunities to stand out from their competitors.
Our PM 2, the first pilot machine to be rebuilt, now adds a new gap former to its previous former, that allows the
production of external packing board at speeds exceeding 2,000 m/min. In fact, top speeds of over 2,500 m/min have
been attained on the machine during pilot runs. PM 1, on the other hand, was rebuilt to be able to more effectively
develop energy-efficient solutions for making layered products utilizing cheaper raw materials, for example.
We are very well equipped also in the field of tissue making R & D. As a matter of fact, our personnel and facilities
located in Karlstad, Sweden are unique in the world. Nowhere else can tissue processes be studied and developed in
the same detail and scale. This offers our customers unbeatable opportunities to excel in the market.
Our service will also improve in the form of an expanded offering. Integration of the paper machine clothing and
filter fabric manufacturer, Tamfelt, with Metso at the beginning of this year fulfils our long-term objective. Tamfelt’s
fabrics complement Metso’s range of products and services, and this allows us to offer more comprehensive and
competitive solutions for the needs of our shared customers.
From the perspective of product development, we now have unparalleled opportunities to develop machines and
machine clothing together, and to add value for our customers through the advances achieved.
We believe, therefore, that our key asset will continue to be our ability to provide customers with the industry’s
most efficient product and service packages, which will also, in the long run, play a responsible role in caring for our
common environment.
Bertel Langenskiöld
President, Paper and Fiber Technology
A completely new
and unique laboratory
cooking system is being
built in Karlstad. Several
improvements are also
being made at the pilot
plant in Sundsvall.
Read more on page 34.
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in this issue

   , .
PO Box 587, FI-40101
Jyväskylä, Finland
Tel. +358 20 482 150
Telefax +358 20 482 151
 
www.metso.com/pulpandpaper/results
--
Riitta-Maija Peltovuori
MANAGING EDITOR
Riitta Räisänen
ASSOCIATE EDITORS
Heli Anttila, Hannele Björkbacka, Annica Börstell,
Björn Engström, Ulf Eriksson, Henrik Karlstedt,
Taru Katajainen, Marianne Kasjan, Markku Käppi,
Susanna Lauritzen, Leena Marttinen,
Taisa Noetzold, Riitta Pöntynen, Kati Railevirta,
Maiju Salenius, Sanna Siren, Eric Tetreault,
Susan Trast, Gunnar Vesterlund, Tim Warriner
  
-   

© Copyright Metso Paper, Inc.
All rights reserved.
Printed on MultiArt Gloss 115/250 g/m
2
Supplement MultiArt Matt 150 g/m
2
Printed on May 24, 2010
Reproduction permitted quoting

“Results pulp & paper” as source.
All product names used herein are trademarks
of their respective owners.
Addresses
Metso Paper, Inc. customer data
ISSN 1798-0933
www.metso.com/pulpandpaper
"We have been fascinated
by the concept of flow-
through for quite a while
now. It was 2005 when
we decided to meet the
challenge and make the
concept a reality. Now
after five years' hard work
we can smile - the fiber
flow simulation revolution
has taken place," chuckle
Markku Partanen (right)
and Jorma Halla, the
creators of the new
OptiFiner Pro refiner.
Read more on page 46.
Featured articles
8 Metso and Tamfelt join together:
A perfect union formed for the
customers
15 'Game-changing' multilayer
curtain coating technology
18 Mondi Świecie ECO7:

Economy meets ecology
35 ITC Bhadrachalam invests
in the future - Ozone bleached
pulp and fine papers
46 OptiFiner Pro refiner:
A revolution in LC refining technology
48 West Coast Paper Mills
builds new production
2 Editorial
4 News in brief
7 Column
Christine Hagström-Näsi,
CEO of Forest Cluster Ltd.:
A period of change
provides a great opportunity
25 Products and solutions
51 Metso around the world
Reporting results
12 At SCA Packaging Munksund
white liquor quality and capacity up
thanks to cutting-edge technology
22 New TwinRoll Evolution cuts
discharges and costs at Zellstoff-
und Papierfabrik Rosenthal
24 HiRun upgrade service
saves energy at Sachsen PM 1
39 HiDrain boosts dry content
at Norske Skog Skogn PM 2
40 Save your energy
- proven concepts create lasting results

42 Infrared trumps nuclear
for tissue quality control
45 Matching baskets
comes down to the wire
4 /    
  
News in brief
Metso rebuilds Alabama River Group’s pulp drying machine
Metso will supply Alabama Pine Pulp with a rebuild of their market
pulp machine in Claiborne, Alabama, USA, as the mill converts to
roll fluff pulp production.
Metso’s delivery will include both a wet end rebuild as well as
the new finishing equipment needed for roll fluff pulp production.
The scope of supply includes a new headbox, steambox, calender
and winder. The rebuild will be completed in stages beginning in
the spring of 2010, with the final completion in early 2011.
Alabama Pine Pulp is part of the Alabama River Group (ARG), a
subsidiary of Parsons & Whittemore Inc., and known worldwide
as a leading producer of quality softwood and hardwood market
pulps. The Claiborne Mill Complex, located at Claiborne, Alabama,
employs 550 people and is recognized as one of the largest
pulping operations in North America. The mill will begin roll fluff
production in the second quarter of 2011.
Tel. +1 770 263 1597
Tel. +1 404 433 0937 and +358 40 740 6178
SWEDSPAN Polska orders complete front end
system for high-density ber board plant
Metso will supply SWEDSPAN Polska, Poland, with a complete
front end system for ultra-thin fiber board production. The
system will be installed at the company’s mill in Bielsk Podlaski,

northeast of Warsaw. The delivery of the system will start in the
fall of 2010.
Metso’s scope of delivery will comprise a complete front
end system from the wood yard to the EVO Defibrator system.
Furthermore, the delivery will include electrical and process con-
trol systems and steel structures, as well as installation for the com-
plete scope of supply. The system will deliver high-quality fiber at
the lowest possible production cost and environmental impact.
SWEDSPAN Polska sp. z. o. o. is part of the international
SWEDSPAN Group and will set up a mill for ultra-thin HDF (high-
density fiber) boards in the Bielsk Podlaski region in Poland. The
SWEDSPAN Group was formed as a spin-off from IKEA’s in-house
furniture maker Swedwood in 2008.
Tel. +46 60 16 57 27
Tel. + 46 60 16 53 76
Domtar converts ne paper machine to u pulp production
Metso has been contracted by Domtar Corporation to rebuild their
PM 5 fine paper machine at their Plymouth, North Carolina, USA,
mill for fluff pulp production. The rebuild project will be complet-
ed in the fourth quarter of 2010.
The existing fine paper machine will be rebuilt and converted
to fluff pulp production. Metso’s delivery will include a new wet
end and a rebuild of the finishing equipment needed for fluff pulp
production. The scope of supply includes a new wire section and a
SymFlo headbox equipped with an IQDilutionPro profiling system,
an IQSteamPro steambox, a new press section, and dryer modifica-
tions including a new hood, as well as reel and winder rebuilds.
The rebuilt 306-in-wide machine (7,772 mm) will produce
fluff pulp in the basis weight range of 420-470 lbs/3000 ft
2

(684–765 g/m
2
).
Domtar Corporation is the largest integrated manufacturer and
marketer of uncoated free sheet paper in North America and the
second largest in the world based on production capacity, and is
also a manufacturer of paper grade, fluff and specialty pulp. The
company employs nearly 10,500 people.
Tel. +1 770 263 1597
Tel. +1 404 433 0937 and +358 40 740 6178
Metso’s fabrics contributed to a world speed record
Holmen Paper Madrid’s PM 62 in Spain ran a new newsprint
machine world speed record on January 25, 2010. The new record
is now set at 2,014 m/min. All critical press felt positions during the
record run were equipped with Metso’s Tamfelt fabrics: TMO with
a non-woven base on the pick-up and first press positions, and
a conventional non-woven base felt on the second press shoe
position.
In addition to the felts, a BlackBelt shoe press belt was contrib-
uting to the record on the second shoe press.
Machine runnability and paper quality were excellent during
the record run, and, as stated by the Holmen Paper Madrid PM 62
crew, Tamfelt’s high-quality fabrics and service demonstrated their
ability to add performance – once again. As of December 28, 2009,
Tamfelt, a world-leading supplier of technical textiles, has been
part of Metso Group.
Tel. +358 400 831 352
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  

Two paper machine rebuilds for Shandong Chenming Paper
Metso will supply two fine paper machine rebuilds for Shandong
Chenming Paper Holdings Limited’s subsidiary mills in China. The
orders are a continuation of Metso’s earlier deliveries to Shandong
Chenming Paper.
Metso’s delivery to Wuhan Chenming Hanyang Paper’s PM 1
in Wuhan, Hubei province, will include a ValSizer film size press,
a TurnFloat air dryer and an upgrade of the after-dryer section.
A rebuild of the press section with a SymBelt shoe press and an
upgrade at the BCTMP (bleached chemithermomechanical pulp)
plant will be supplied to Shouguang Chenming Art Paper’s PM 5
in Shouguang, Shandong province. The rebuilt Wuhan PM 1 is
scheduled to start up in late 2010, and the rebuilt Shouguang PM 5
in 2011.
Wuhan Chenming Hanyang Paper Co., Ltd. and Shouguang
Chenming Art Paper Co., Ltd. are subsidiaries of Shandong
Chenming Paper Holdings Limited, one of the biggest paper
producers in China. In 2008, the company’s paper production
capacity was over 3 million tons, turnover over EUR 2.0 billion and
the number of employees 17,000.
mikko. Tel. +358 40 841 8804
Metso establishes future pulp mill biorenery
concept with Stora Enso and Domtar
Metso, Stora Enso and Domtar have established a project to
develop a future pulp mill biorefinery based on new pulping tech-
nology. The target is to develop a new concept with better energy
efficiency and cost effectiveness, lower initial capital investment
costs and reduced fiber usage, while maintaining or even improv-
ing the fiber properties from a paper and board quality point of
view. The project will take several years.

Metso, Stora Enso and Domtar see promising opportunities
for a breakthrough in sustainable chemical pulping technology,
compared to current practices.
The new pulp biorefinery concept will further strengthen
Metso’s position as the leading supplier of sustainable technology
to the pulp and paper industry.
The project is in line with strategic targets set by the Finnish,
Swedish and North American forest clusters for their research and
development work: to renew the industry, to efficiently utilize bio
raw materials, to protect the environment, and to improve cost
efficiency.
Stora Enso Oyj is a renowned manufacturer of pulp, paper,
board, bio energy and other wood-based materials, chemicals and
products, and is continuously seeking to improve and develop its
processes and products. The company is in possession of valuable
experience and know-how relating to chemical pulp quality and
its impact on paper and board quality and added value for paper
and board users.
Domtar Corporation is the largest integrated manufacturer
and marketer of uncoated free sheet paper in North America and
the second largest in the world. Domtar also manufactures paper
grade, fluff and specialty pulp. Domtar is in possession of valuable
experience and know-how relating to the manufacturing, quality
and use of chemical pulp in paper making.
Tel. +358 40 507 6946
Zhejiang Ji’An orders containerboard line
Metso will supply the Chinese Zhejiang Ji’An Paper Packet Co.,
Ltd. with a containerboard production line for their mill in Haiyan
county, Jiaxing city, Zhejiang province. The start-up of the produc-
tion line is scheduled for the second quarter of 2011.

Metso’s delivery will include a complete containerboard machine
from the 3-ply multi-Fourdrinier forming section equipped with a
ValFormer top forming unit to the reel. The fully automated ValReel Pro
reel features unique one-level reeling technology. The Metso automa-
tion package will comprise process, machine and quality controls.
The 7.25-m-wide (wire) PM 3 will be the fastest coated board
machine in the world at the design speed of 1,200 m/min. The
daily production capacity will be approximately 1,900 tonnes
of coated white top testliner in the basis weight range of
130-280 g/m
2
out of bleached kraft pulp, deinked pulp, mixed
waste and OCC (old corrugated containers).
Zhejiang Ji’An Paper Packet Co., Ltd. is a subsidiary of Shanghai
Taison Pulp & Paper Group. Zhejiang Ji’An currently produces con-
tainerboard on two Metso-supplied machines, the PM 1 started
up in 2008 and the PM 2 started up in 2006. The company’s annual
production capacity is around 750,000 t/a.
hannu.t.pietila@)metso.com Tel. +358 40 503 4085
Shandong Bohui in China starts up coated board line
The Metso-supplied coated board production line delivered
to Shandong Bohui Paper Industry Co., Ltd in the city of Zibo
in Shandong province, China, came successfully on stream on
December 31, 2009. The new 6.25-m-wide BM 2 produces close to
1,400 tonnes of folding boxboard per day.
“We started small but are growing steadily. Our plan for the fu-
ture is to become the largest coated board producer in China. The
Metso-supplied BM 2 is an important step towards our target and
we believe that with the new machine we will be the top quality
supplier of coated board in China,” says Yang Yanzhi, Project

Director of BM 2, Shandong Bohui Paper.
Metso’s scope of supply comprised an all-online coated board ma-
chine from headbox to winders with related stock preparation and
air systems, as well as a BCTMP (bleached chemi-thermomechanical
pulp) plant. The complete automation systems package included
quality controls, runnability and condition monitoring systems.
6 /    
  
The line’s technological features include a 3-ply multi-Fourdrinier
forming section equipped with ValFormer shoe blade forming tech-
nology and a ValZone metal belt calender, enabling raw material sav-
ings and ensuring excellent printability of the board. Coating drying is
carried out with highly energy-efficient PowerDry Plus air dryers that
consume up to 50% less energy than conventional infrared dryers.
BM 2 was started up with Metso’s Tamfelt fabrics in the forming,
press and dryer sections, and BlackBelt shoe press belts. Tamfelt, a
world-leading supplier of technical textiles, has been part of the
Metso Group as of December 28, 2009.
Shandong Bohui Paper employs approximately 5,000 persons.
The annual paper and boardmaking capacity is around 1.25 million
tonnes.
Tel. +358 40 585 7476
Saica Containerboard in the UK orders containerboard line
Metso will supply a lightweight containerboard production line to
Saica Containerboard UK Ltd at Partington Wharfside, in Trafford,
near Manchester in the United Kingdom. The start-up of the pro-
duction line is scheduled for the first quarter of 2012.
Metso’s delivery will include a complete OptiConcept paper
machine, including an approach flow system, pulpers and air
systems. Sheet strength and uniformity will be produced by an

OptiFlo headbox and an OptiFormer gap former. The whole pro-
duction will be handled by a WinDrum Pro high-capacity winder. A
comprehensive Metso automation package will comprise process,
machine and quality controls. A Metso process control system will
also be supplied for the new combined heat and power station at
the Partington mill.
The design speed of the 8.2-m-wide (wire) PM 11 is 1,700 m/min.
The annual production capacity will be approx. 400,000 tonnes of
testliner and fluting in the basis weight range of 75-125 g/m
2
, out
of 100% recycled furnish.
Saica Containerboard UK Ltd is a subsidiary of SAICA. SAICA is a
family-owned Spanish company and a world leader in the produc-
tion of lightweight corrugated containerboard from recovered
paper. The company currently employs over 8,000 people in Spain,
France, Portugal, Italy, Ireland and the UK. SAICA has an annual
turnover of EUR 2.2 billion.
Tel. +358 40 838 8950
Cheng Loong Corporation orders board making technology
Metso will supply board making technology to Cheng Loong
Corporation for their new containerboard production line at
Hou-Li paper mill in Taiwan. The production line is scheduled to
start up in the second quarter of 2011.
Metso’s delivery will include three ValFlo headboxes for the
3-ply liner machine with an IQDilution Pro dilution profiling system
for the back ply, a ValPress press section and a ValSizer film size
press. The dryer section will be equipped with an IQAquaPro mois-
turizing unit for web moisture profile control.
The daily production capacity of the 7.25-m-wide (wire) PM 10

is up to 1,400 tonnes of kraft top and testliner in the basis weight
range of 100-280 g/m
2
at a maximum running speed of 1,000 m/min.
Established in 1959, Cheng Loong Corporation has four paper
mills and five paper box plants in Taiwan. The company’s annual
production capacity of paper and paperboard is approx. 1.8 million
tonnes.
Tel. +358 40 503 4085
Propapier in Germany starts up papermaking line
The Metso-supplied papermaking line of Propapier PM2 GmbH
came successfully on stream on March 15, 2010 at Propapier’s
greenfield mill site in Eisenhüttenstadt in Germany.
The new PM 2 line will annually produce up to 650,000 tonnes
of testliner and fluting grades in the basis weight range of
70-130 g/m
2
out of 100% recycled fiber.
The gigantic 10.85-m-wide PM 2 features state-of-the-art paper
making and automation technology by Metso, from the stock
preparation plant to the OptiConcept paper machine. The design
speed of the machine is 1,900 m/min. A two-year cooperation
agreement will support the systematic optimization of the produc-
tion and quality of the line.
The start-up teams of Propapier and
Metso after the successful start-up of PM 2.
Raimo Tuominen, Metso’s Project Manager, describes the com-
missioning and start-up of the line as very successful, in terms of
schedule and co-operation with the motivated Propapier site team.
Götz Herold, Mill Manager of Propapier PM2 GmbH: “Thanks

to the excellent commissioning work during the last few weeks
we were able to successfully start the production of saleable
Wellenstoff (corrugating medium) with a basis weight of 90 g/m
2
at
a speed of 1,250 m/min on the planned start-up date of March 15,
2010. A world-class mill of the highest technical level has been built
in Eisenhüttenstadt.”
Propapier PM2 GmbH is part of Progroup AG, a group of com-
panies offering products and services for the corrugated board-
converting industry. After the start-up of PM 2, the annual tonnage
of Progroup AG’s two paper mills will equal 1 million tonnes of
containerboard.
Tel. +358 40 833 4985
PHOTO: Propa p ier
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
The forest industry is undergoing a signifi-
cant global transformation. The world’s
emerging economies, such as China and
Brazil, are competing in the forestry market,
not only with low production costs but
also with more and more competence, ad-
vanced technology and innovations. The
Finnish forest industry is also increasingly
moving over to Asia and South America to
be nearer to the rapidly-developing mar-
kets and fast-growing wood raw material.
The world’s paper consumption has
quadrupled over the past 40 years and

it is still growing. The growth of paper
consumption has, however, slowed in the
Western world and for some paper grades
it has even started to decline. In spite of a
maturing market, paper will continue to
have a major role also in European industry.
Europe is still responsible for a good third
of the more than 380 million tonnes of
paper produced in the global market.
Efficient production technology that uses
less resources, and comprehensive control
systems help to increase the competi-
tiveness of the entire forest cluster. New
technologies and solutions can also be
used to reduce the costs of climate change
and emissions trading and promote the
realization of sustainable development
targets. Therefore, promotion of sustain-
able development is a key objective of
changes made to production technologies.
In the future it will be necessary to be able
to control a product’s entire life cycle, from
purchasing the raw material to recycling.
Biorefining is turning into a significant
new area of growth. Raw materials for
the bio fuel industry can be produced by
intensifying the use of wood and making
use of various waste flows. The EU’s emis-
sions targets are speeding up develop-
ment of these markets. Wood fibers will be

utilized even more diversely in the years to
come, for example in packaging, various
intelligent products, drugs or foodstuffs. In
the future new kinds of synthetic cellulose
fibers may replace cotton, the cultivation
of which requires lots of water, chemicals
and space. Nanocellulose is a porous new
material which can be made into transpar-
ent film or extra-strong paper, for example.
In the future, materials produced from
wood could even be used instead of plastic
in many of its current areas of use.
In Finland the wood processing industry
and suppliers of equipment and chemicals
have a long history of cooperation in the
development of production technologies
and this provides a competitive advantage.
Even existing plants are able to employ di-
verse and efficient energy use and benefit
from secondary flows. Finnish strengths
are excellent technological competence
and the ability to make use of technology
in products and production. Technological
competence will provide a strong basis for
competitiveness also in the future.
In order to produce innovations many
different factors are required at the same
time in addition to technology: financing,
knowledge of the markets and distribution
channels, a functional organization and

business model, and brand competence.
An understanding of the value chain is also
very important. Each contributor should
know his/her place in the chain from the
production of raw materials through vari-
Christine Hagström-Näsi
CEO, Forest Cluster Ltd
A period of change
provides a great opportunity
ous applications to the manufacturing of
the end product.
Many companies are now required
to find new customers, enter new areas
and come up with new and competitive
operating models. Customers are more
receptive to new suppliers if their products,
services and business concepts provide
benefits and cut costs or spread risks in
the business. This kind of transformation
phase provides a great opportunity for
developing operations.
In the midst of increasingly rapid
change we all face the major challenge
of trying to understand what is actually
going on. We are unable to affect all of the
changes taking place, so we need to be
able to react sufficiently early while also
predicting what is to come. Insight and
opinions alone are not enough – action
is also needed. When changes have been

discovered, an actor is needed to tackle
the change and take action.
Building the future will require a new
way of rapid networking where ideas are
freely available and open to further devel-
opment. It will be important to share our
ideas and build on the ideas of others, and
to develop a culture of give and take.
Forest Cluster Ltd was established in spring 2007 to lead the sector’s stra-
tegic cluster of expertise and to implement the objectives set out in the
research strategy for the Finnish forest cluster, published in fall 2006, to be
the world’s leading forest cluster by 2030. Forest Cluster Ltd provides a new
basis, which functions on the principle of open innovation, for cooperation
and building a future for top-level research and the key companies in the
sector.
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 
Metso and Tamfelt join together
A perfect
union formed
for the customers
Metso and Tamfelt are both
house-hold names identified
with high-performing paper
and board machines around
the world. The combination
of the two companies will
provide papermakers with
access to a more competitive
and comprehensive product

offering as well as more extensive
process improvement and service
packages from one source.
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 
OVER 210 YEARS OF TAMFELT
From sheep to innovative technical textiles
Founded in 1797, Tamfelt is one of the pioneers of Finnish industry. The
inspiration for starting up the mill came from Jokioinen Manor, which had
a large herd of sheep. The owner of the manor wanted to produce cloth
from the wool using the new English machine method.
By the 1840s, the mill was the biggest in its field in Finland with more
than a hundred workers. Due to lack of a water supply, the operations
were moved to Tampere where production started under the name of
Tampereen Verkatehdas Oy - Tammerfors Klädesfabriks Ab in 1859.
The manufacture of machine felts began in 1882. This was the first step
that was to take the company away from traditional textiles and into the
realms of the paper industry.
In 1960, the felt mill’s sales exceeded those of the woolen mill. The focus
of production had shifted for good. Exports started in 1956. The produc-
tion of filter fabrics began in 1965, and from then on the company focused
on technical textiles.
In 1981, the name was changed to Tamfelt Corp. Internationalization
started in the 1990s and the company has plants in Finland, Portugal, Brazil,
Poland and China.
As of December 28, 2009 Tamfelt has been part of Metso Group.
TEXT Marjaana Lehtinen
“The topic

of having

paper ma-
chine clothing (PMC) products of our own
has been under discussion for decades
at Metso. The acquisition of Tamfelt was
in fact a natural step since fabrics are an
essential part of a paper or board machine.
The larger and faster a machine is, the
more the fabrics and the machine form a
whole. This has lead to a situation where
cooperation between a machine supplier
and a PMC manufacturer is a must,” says
Bertel Langenskiöld, President of Metso’s
Paper and Fiber Technology segment.
Metso’s predecessor Valmet made a
farsighted decision back in the 1970s to
acquire some of Tamfelt’s shares, and the
companies have been cooperating closely
in product development and customer
Metso for 26 years, for example, as head of
the paper and board machines business, as
plant manager in Rautpohja, Jyväskylä, and
as head of Metso Paper’s research, technol-
ogy and development operations.
By late December 2009, Metso had
acquired 98% of Tamfelt’s shares, making
Tamfelt officially a part of Metso. The process
of integrating operations has been proceed-
ing rapidly ever since. Tamfelt now makes
up the Fabrics business line in Metso’s Paper
and Fiber Technology segment.

Building bridges
The two technology leaders and full-scope
suppliers in their own areas are a strategi-
cally perfect match; there is no overlapping
in their product offerings. They know each
other well. The fact that both companies
have their roots in Finland and share the
same business culture is expected to make
the integration process smoother.
“For Tamfelt the worst scenario would
have been for Metso to join forces with a
foreign PMC manufacturer,” Kerttula ad-
mits. “Generally speaking, we would have
been in quite a challenging situation trying
to grow on our own in the future. Metso
and its global network provide us with to-
tally different opportunities and resources
to take care of our products, improve and
sell them.”
cases ever since. According to Langenskiöld,
last fall seemed like the right time to move
on to the next stage and deepen the rela-
tionship even further. Before that, all other
options had been carefully studied in order
to find the overall best solution for Metso.
Out of the possible alternatives, Tamfelt was
chosen as ‘The One’.
“Although the two companies had been
‘dating’ for a long time, the proposal was
somewhat unexpected,” recalls Reima 

Kerttula, former President and CEO of Tamfelt,

now President of Metso Fabrics business line.
Tamfelt’s new owner is no less than Kerttula’s
former long-time employer. Before joining
Tamfelt in January 2009, Kerttula worked for
continu ed over leaf…
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 
About 40 percent of the world’s paper is
produced on Metso machines. For Tamfelt,
as a relatively small player, this large
installed base creates new opportunities,
especially outside Europe.
Kerttula says, “But it also works the
other way around too, since our PMC
products can be found at mills where
there are no Metso machines. In fact, after
hearing the news, many customers told us
that Tamfelt can function as a bridge and
bring Metso’s solutions to places where
there aren’t any. I believe that this will take
place.”
Filter fabrics, in turn, fit in very well with
Metso’s offering that supports recycling
and improves the environmental perform-
ance and operational eco-efficiency of cus-
tomers’ production processes. For example,
its filter bags are used in power plants’ flue
gas cleaning systems.

“Filter fabrics complement Metso’s selec-
tion of wear products, not only in the pulp
and paper industry but also, for example,
in the mining and energy industries,”
Langenskiöld adds.
More comprehensive
product and service oerings
In recent years, the change in the pulp and
paper industry has directed customers’
demand towards service, maintenance and
optimization of their production proc-
esses. The addition of Tamfelt’s products
will further strengthen Metso’s global sales
and service network capabilities.
Customers will now have access to a
more competitive and comprehensive
product offering as well as wider process
improvement and service packages from
one source: Metso. By starting up their
machines with Metso’s clothing, customers
will gain added value. With fewer partners
involved, communication will be more
straightforward and things will be done
faster.
“Metso’s target is to provide customers
with a comprehensive solution including
the machine, automation, clothing and
service. Having all this in-house helps us
develop the whole paper and board indus-
try,” Langenskiöld continues. “Acquiring our

own PMC products is one element of our
plan to support our customers in improv-
ing process performance and results.”
The combination of advanced machine
technology and innovative PMC products
has already brought success to many
customers especially on wide, fast paper
machines. Tamfelt’s fabrics have contribut-
ed to the achievement of many speed and
production world records run with Metso
machines, such as Stora Enso Kvarnsveden
“This combination
means for Metso’s and
Tamfelt’s dedicated and
motivated professionals
the opportunity to work
together to develop
and find increasingly
efficient solutions for
our customers’ needs,"
says Bertel Langenskiöld, President
of Paper and Fiber Technology.
PM 12 in Sweden, UPM Changshu PM 1 and
APP Ningbo PM 6, both in China.
Ability to create totally
unique products
Product development between the
two companies goes back a long way
and is visible in high-performing paper
and board machines around the world.

Innovation has always played key role for
both companies – and will continue to do
so now that they are combined.
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 
In future, product development will be
further intensified and significantly deep-
ened. Inside this one Metso family, it will be
possible to create something totally unique.
“Cooperation will be closer; there will
be no trade secrets since we now share
the same targets. This will accelerate
product development,” Kerttula points out.
“However, PMC cooperation with custom-
ers will continue as before. Our customers
are used to buying a complete PMC pack-
age, including knowhow, training, and joint
product development, not just fabrics.”
Towards more economical,
higher-performance machines
Both Bertel Langenskiöld and Reima
Kerttula are confident about the future
and they are convinced about the many
benefits brought to everybody by this
combination.
“It will provide Metso with an oppor-
tunity to develop more economical and
higher-performance machine solutions.
We will be able to improve our service
capabilities and offerings globally. Our

customers will benefit by getting more
comprehensive service and expertise from
us,” Langenskiöld sums up.
“Although the pulp and paper industry
has in the past few years faced some dif-
ficult times, we still consider it a very impor-
tant customer segment at Metso. We will
continue to focus on it also in future and will
not leave our customers in the lurch. The
acquisition of Tamfelt’s PMC and filter fabric
products is one example of our efforts.”
Riaupaper PM 1 and PM 2 run full speed
ahead with Metso fabrics and machinery
Metso’s fabrics have had a significant effect on the dewatering efficiency
and runnability of the Metso-supplied Riaupaper PM 1 and PM 2 in
Indonesia. Both machines produce premium-quality office paper.
The press felts have been running successfully on both machines since
their start-up in 1998 and 2006, respectively. Riaupaper selected a Metso
felt package for its PM 2 based on the good experience and results of
the cooperation gained on PM 1 and the quality of the fabrics. A good
fabric reference from another OptiConcept machine in Asia also played an
important role in the decision making.
The press felts perform outstandingly and have guaranteed premium
paper quality throughout the effective felt lifetime. Co-operation pro-
grams and on-site support have produced results in production by ensur-
ing that the right felts are running.
The 9,350 mm wire width Metso-supplied machines are among the
fastest uncoated woodfree paper machines in the world and they are
used as a benchmark by other office paper suppliers. In August 2008, PM
2 reached a new 24-hour record of 1,667 m/min, exceeding the design

speed of 1,600 m/min by a considerable margin. It is one of the top three
fastest uncoated woodfree paper machines in the world. PM 1 recently
set a new speed record of 1,510 m/min. It is operating continuously above
1,500 m/min, which is equally clearly above the original design speed of
1,340 m/min.
Riaupaper PM 1 SymPress B press section
• Pick-up felt, 1st press and 2nd press: Ecostar
Riaupaper PM 2 OptiPress press section
• Pick-up felt: EcoAqua
• 1st press bottom felt: Aquastar
• 2nd press top felt: Ecostar
For more information visit:
www.metso.com/fabrics
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 
The pressure disc white liquor filter,
PDW, Metso installed at SCA Packaging
Munksund AB during 2008 performs the
same function as the white liquor sedimen-
tation vessel it replaced. The vessel and the
PDW both separate white liquor and lime
mud for further use in the pulping process
at the mill. But that’s where the comparison
ends.
Compared with the corroded and worn-
out sedimentation vessel installed in 1966,
the brand new PDW yields more white
liquor of higher quality.
What’s more, the footprint of the PDW is
significantly smaller than that of the sedi-

mentation vessel. And it is dimensioned to
allow increased capacity, not only in the
future but also currently, when more white
liquor than usual is needed for one reason
or another.
SCA Packaging Munksund AB, located
in Piteå, Sweden, produces 340,000 tpy of
kraftliner from softwood and hardwood,
recycled fiber and sawmill chips. Kraftliner
is used in the production of industrial
packaging, printing applications and high-
demand corrugated packaging.
Scope of supply
Apart from the PDW filter and auxiliary
equipment, Metso supplied the Munksund
causticizing plant with a new causticizing
vessel and a green liquor cooler - see Figure
1, showing the causticizing process line.
According to Arne Lundman , Building
Design Engineer at Munksund, the condi-
tion of the sedimentation vessel was such
that the government authorities strongly
recommended replacing it as it was be-
coming an environmental hazard. What’s
more, he notes, it produced white liquor of
poor quality.
In his role as a designer at the mill,
Lundman was grateful for the 3D computer
program Metso is able to offer custom-
ers. “The PDMS 3D computer program is

of enormous help in designing the layout
of a building to house a PDW. It is of great
advantage to be able to see what the
facility is going to look like and how it will
function before it is actually in place,” says
Lundman.
Lundman and Annette Nilsson, Process
Engineer recovery line at the mill, were
instrumental in the research conducted
into the various technologies and suppliers
available for white liquor and lime recovery.
According to them, they selected the pres-
surized white liquor filter technology over
the other options because it is the most
AT SCA PACKAGING MUNKSUND
White liquor quality and 
capacity up thanks to 
cutting-edge technology
TEXT David Wold
Annette Nilsson, Process Engineer recovery line and Per Nilsson, Operator, at SCA Packaging
Munksund AB together with Jonas Lundgren from Metso during start-up of the new PDW filter.
    / 13
 
modern technology available today. The
fact that Metso staff were involved in the
original development of this technology
contributes to the confidence they have in
Metso as a supplier.
“White liquor quality
our rst consideration”

“Our first consideration when looking into a
new white liquor facility was quality. Metso
guaranteed a solids content of 50 mg/liter
in the white liquor during commissioning.
We are now running at 20 mg/liter or less.
The former facility ran at a solids content of
50 mg/liter or more. This caused cooking
problems and specks in the paper and
board products we produce. It also nega-
tively affected paper machine availability,”
says Nilsson.
“Our second consideration was capac-
ity, which, before the new installation,
was 2,100 m
3
of white liquor/24h. The
new installation increased the capacity
to 3,300 m
3
/24h. This is actually more
than we need for normal operations. On
Pressure disc lter
PDW is a compact
fully automated
machine that produces
crystal-clear white
liquor and washes lime
mud simultaneously.
Fig. 1. SCA Packaging Munksund AB causticizing - 3,300 m
3

of white liquor/24 h.
M33 612A
Hot water
Condensate
Compr. air
Green liquor from
smelt dissolver
Weak liquor to dissolver
Hot water
White liquor to
digester 3,300 m
3
/d
Lime mud
to kiln
Grites
3,432 m
3
/d
3,504 m
3
/d
3,300 m
3
/d
Equalizing
tank
Option 1
Clarier Dregs
tank

Filtrate
tank
Dregs press
Slaker Causticizers
Lime mud storage 1 & 2
PDW lter
Lime mud lter Weak liquor
storage
White liquor storage 1 & 2
Storage
Option 3
Make up silo
Green liquor cooler
Hot water
Cold water
New equipment
Existing equipment
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Here’s what Munksund expected and what they got
Crystal-clear white liqu or. White liquor out of the new PDW at SCA Packaging Munksund AB has a solids content
of 20 mg/liter or less. The former facility ran at a solids content of 50 mg/liter or more, which caused pulp cook-
ing problems and specks in the mill’s paper and board products, as well as poor paper machine availability. These
problems are now history.
Capacity o ptions. The new installation increased the capacity from 2,100 m
3
of white liquor/24h to 3,300 m
3
/24h,
more than is actually needed for normal operations. This gives Munksund the option of running at a higher capacity
if needed, while allowing for additional production capacity in the future. Additional discs can be added for even

greater capacity increases.
Small footprint. The PDW pressurized white liquor filter is a compact, fully automated machine that produces
crystal-clear white liquor and washes lime mud simultaneously. The machine’s footprint at Munksund is significantly
smaller than that of the sedimentation vessel it replaced.
the other hand, it gives us the option of
running at a higher capacity if we need
to catch up after a stoppage somewhere
in the process. It also allows for additional
production capacity in the future.
We had some problems with leaking fil-
ter cloths in the beginning and this caused
higher solids content in the white liquor
than we expected. But Metso corrected
the problem, and now we are running with
high availability and very acceptable solids
content,” says Nilsson.
Produces white liquor
and washes lime mud
The PDW pressurized white liquor filter is
a compact, fully automated machine that
produces crystal-clear white liquor and
washes lime mud simultaneously. Its unit-
type shaft, no-blow design, high-pressure
cake washing and cloth cleaning ensure
high specific capacity, high white liquor
purity and minimum maintenance.
With an extremely high white liq-
uor yield of more than 95%, the PDW
eliminates the need for separate lime mud
washing and reduces the flow through the

green liquor handling, slaking and caus-
ticizing. These features reduce upstream
equipment sizing and facilitate plant
upgrading.
Filtering in three steps
The PDW filter sequence is carried out in
three steps: pre-coating, filtration and
washing - see Figure 2.
During pre-coating, the vessel is filled
with a high flow of causticized liquor to
form a lime mud pre-coat on the filter
discs, which serves as the active filter me-
dium during filtration.
Gas lifters prevent sedimentation of the
causticized liquor in the bottom of the
vessel. Discharge scrapers scrape off excess
Causticized liquor from
slaking and causticizing
Compressed air
Condensate
White liquor to storage
Lime mud to storage
Fig. 2. PDW filter sequence.
lime mud from the filter discs, which is
then flushed to a lime mud mix tank.
During filtration, cake head washers
wash the lime mud cake accumulated on
the filter discs. Discharge scrapers scrape
the washed and dewatered lime mud from
the discs. It then falls through discharge

chutes, where it is flushed with warm water
into the lime mud mix tank. The slurry from
this process is pumped to the lime mud
storage tank and the filtrate is pumped to
the white liquor storage tank.
The scrapers are automatically actuated
at regular intervals to renew the intermedi-
ate layer of the pre-coat. This procedure
keeps the filter medium free of plugging.
The washing sequence cleans the filter
cloths on the discs. When this sequence
starts, the filter feed is interrupted, the
scrapers are advanced to their inner posi-
tion and the vessel drained. When it is
empty, the medium-pressure water show-
ers located above the scrapers remove the
pre-coat and washing is completed.
An acid wash instead of a water wash is
occasionally required to maintain the ca-
pacity of the filter. This procedure involves
discharging acid through the cake wash
showers. The acid is discharged into the
lime mud vessel and then pumped to the
lime mud storage tank.
Thomas Malmqvist
Sales Manager
Tel. +46 70 310 53 22

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 
Multilayer curtain coating has the
potential to revolutionize the art
and science of paper and board
coating, allowing precise, cost-
effective coverage of the base sheet
to get the tailor-made functionality
desired. Interest in this technology is
growing rapidly around the world.
‘Game-changing’ multilayer curtain coating technology
Are you ready?
TEXT Hugh O’Brian
imagine

being able to put coating and functionality simul-
taneously in multiple layers in your sheet, precisely
where it is needed, and in exactly the right amount. And then consider the
significant cost advantages of doing it at very high speeds in a clean, quiet,
non-contact operation.
Actually, you don’t need to imagine this: some papermakers are already do-
ing it! And many more are now actively assessing a revolutionary new coating
system to see how they can apply it to existing grades and, perhaps much
more importantly, create new products.
Stig Renvall, Senior Paper Technology Manager (right) says that the advantages of OptiLayer multilayer curtain coater in terms of cost, quality and operational efficiency are very
clear. Reijo Kaipainen, Coater Operator, welcomes you to take full advantage of the pilot multilayer curtain coater at Metso's Surface Treatment Technology Center.
16 /    
 
The technology is Metso’s new OptiLayer
multilayer curtain coating system, which
adds several different coating layers to the

web at the same time in a non-contact
operation with essentially no speed restric-
tions. This gives extremely high efficiency
with regard to coating chemicals, machine
runnability, drying efficiency and overall
cost of the process. The coating follows the
contour of the sheet for complete and even
coverage of the web.
The process was developed by Metso
in close cooperation with the coating
formulation supplier Dow Chemical. The
two companies have cooperated in the
development of this technology for paper
and board manufacturing applications.
One of the leaders in the use of
OptiLayer is Dong Il Paper in Korea, which
has succeeded in producing and market-
ing a new white liner grade based on 100%
recycled brown stock. Thus brown simply
becomes white in a single, cost-effective
coating step. No bleaching, no white fiber.
Did we miss something?
The results from Korea have certainly got
attention at technical presentations and
conferences held in Europe recently. “Many
of the testliner makers we have talked to
appear a bit anxious, or even nervous, that
they might have missed something when
they heard about what Dong Il has been
doing,” explains Tim o Saresvuo, Sales

Manager at Metso. “Since those results
became public in late 2009 there has been
a very noticeable increase in the level of
interest in the multilayer curtain coating,
and in the trial activity on our Technology
Center pilot line.”
The OptiLayer technology is based on
curtain coating methods that have been
around for a fairly long time. What is new
and revolutionary is the multilayer aspect
and its successful commercial application
in installations around the world. While
there is a fair amount of secrecy sur-
rounding some of the installations, two of
them, Dong Il in Korea and Jujo Thermal
in Finland, have been willing to discuss
their results. In both of these cases, the
companies have used this new technol-
ogy to develop products, processes and
functionality that has helped to keep them
a step ahead of the competition.
What Dong Il Paper did
At its Ansan mill near Seoul, Dong Il rebuilt
a brown liner machine with the OptiLayer
multilayer curtain coater. It was therefore
able to launch two new grades based on
100% recycled brown fibers, which it calls
WL (White Liner) and CWL (Coated White
Liner), taking a market share on the Korean
market. Although Dong Il had no previous

experience with coating, the unit easily
started up in December 2008 and has been
running very well for more than a year.
“The multi-layer curtain coater
gives us wide flexibility by
putting the right properties
in the right place at the right
cost,” explains Jin-Doo Kim, Vice President
and Technical Manager at Dong Il. “Titanium
dioxide for light scattering, for
example, can be put in the
second layer from the top,
which frees up the top layer
for printability adjusting and
fine tuning. This means ratio
adjustments for properties like
brightness can easily be made
on the run. At the same time,
the precise curtain coating
method gives much lower
coating waste and broke.”
Kim says it wasn’t easy to push his ideas
through, but he was successful eventually.
“Actually,” he says, “many people consider
me a trouble maker! Since I originally came
from the fast moving electronics business,
I generally refuse to accept the normal way
of thinking in the paper industry. But by
questioning the normal mode of doing
things, I think we can move forward, and

we must, as it is really a matter of survival
Jujo Thermal used the unique technology to create a new extra-long durability thermal paper grade.
Operating principle of
OptiLayer multilayer
curtain coater: Coating
colors can be customer
tailored to get the optimum
function at the right cost.
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 
Although producers of liner and spe-
cialty grades have been among the most
active in adopting the OptiLayer multilayer
curtain coating technology, other grades
can also benefit. Depending on the grade,
payback can be very rapid, as short as one
year based on some calculations for sav-
ings in fiber and coating costs.
Replace the airknife on coated board
“Coated board, which has used airknife coat-
ing for a long time, could get great benefits
from the curtain coating method,” says
Renvall. “Airknife coating has low efficiency
due to inherent runnability and speed limita-
tions, as well as other problems such as noise,
mist and coating reclaim. A curtain coater
could provide the same or better coating
coverage as an airknife, in a faster, cleaner,
quieter and more energy efficient operation.”
High-quality inkjet photo paper is also

seen as a grade that could take advantage
of this technology. “I am a bit surprised that
inkjet photo paper isn’t using this yet,” com-
ments Renvall. “It is a perfect fit and certainly
the right equipment to make it cost effec-
tively. But perhaps because the OEM printer
makers have such a strong hold on the mar-
ket and product specs, the paper suppliers
don’t dare to consider any other technology.
I am sure it will eventually come through.”
“Along those lines,” continues Renvall,
“I don’t think it is too controversial
to say that the paper supply
chain is risk-averse. No one
wants to take risks or try a new
product that doesn’t exactly
meet the specs that have always
been valid for that grade. But
if you look at what Dong Il
has done in Korea, they just
didn’t worry about the specs
and launched a new grade
that is working very well. It
might be what you could term
‘politically correct downgrading’.
If there are very clear cost,
quality and operational
advantages, the specs can be
adjusted. After all, what is more
important, specs or profits?”

That’s a good question and it seems
pretty clear that this new multilayer curtain
coating technology does have the poten-
tial to be a ‘game-changer’. Perhaps the
bigger question is: How will it impact on
your company and your business?
A challenge for everyone
To use the potential effectively will require
innovation not only from the paper-
makers on the production floor or the
technical people working with R&D but
also the sales managers who will have
a new improved grade to sell and the
higher company executives who must find
unique ways of gaining a cost and market
advantage over competing products. How
many paper industry CEOs and CFOs, or
even sales managers, know what a mul-
tilayer curtain coater is? Now might be a
good time for them to find out.
Stig Renvall
Senior Paper Technology Manager
Tel. +358 40 559 1693

The new white coated board from Dong Il,
using only brown fibers for furnish, has been
extremely successful in the market.
for the paper industry. The only way to stay
alive is to move fast!”
Jujo Thermal pushes innovation as well

Another company that has moved fast is
Jujo Thermal in Kauttua, Finland, which
started up the first commercial installation
in the world of the OptiLayer curtain coater
in 2006. The mill makes high-quality ther-
mal printing papers and was looking for
ways to improve cost efficiency. By laying
down several layers at once in the exact
quantity needed with almost no coating
waste, the multilayer curtain coater was the
perfect solution.
Technical Director Matti-Pekka Vanninen
comments that the new coater “allows us
to apply a very thin layer that follows the
contour of the web, meaning we apply
exactly what we need in the right place to
get an extremely even coat profile. In addi-
tion, since we apply multiple layers at once
in one station, we get improved drying ef-
ficiency as we only need one pass through
the dryers to dry several layers. This is very
energy efficient and the entire process gives
us excellent total cost efficiency.”
The incredible shrinking
R&D and tech departments
All of the efficiency and cost advantages that
OptiLayer offers should get a high level of at-
tention from the paper companies. However,
a very real barrier to implementation of new
technology in the pulp and paper industry

is the fact that over the past decade or so,
most companies have made drastic cuts in
their R&D and technology staff.
Stig Renvall, Metso’s Senior Paper
Technology Manager, is a real expert in
curtain coating. He has also worked for a
major US paper producer for many years.
“I have seen the situation from both sides
and it is clear that many paper companies
have ‘outsourced’ their R&D activities to the
machine and chemical suppliers over the
past decade. So it is a big challenge for the
paper companies, even more so than in the
past, to evaluate and adopt a revolutionary
new technology like OptiLayer. But this is so
unique that we are getting their attention,
especially from the fast moving companies.”
18 /    
 
ECO7
which produced its first
reel on September 1, 2009,
is Mondi’s response to the growing trend
towards lightweight corrugated case
material. The trend, in turn, is driven by de-
mand for higher cost efficiency, European
packaging legislation and environmental
concerns.
The new line is ideally located to serve
customers in Central Eastern Europe, as

well as in Germany, Scandinavia and
Benelux. EUR 305 million investment,
combined with a new state-of-the art box
plant, strengthens Mondi’s position in the
corrugated business by adding lightweight
containerboard to its portfolio. With ECO7
increasing capacity by 470,000 tons per
year, the mill’s production will exceed one
million tpy.
“I see Mondi Świecie emerging as the
preferred solutions provider for container-
board in Europe. Customers will automati-
cally identify it as the best supplier, and
competitors will identify it as the best
benchmark. We intend to become the cen-
ter of competence for Mondi in the field
of corrugating papers,” says Maciej Kunda,
CEO of Mondi Świecie SA.
Consumption of recycled container-
board in Poland has grown at an annual
rate close to double digits. Earlier, its raw
material was to a great extent imported
from Western Europe, mostly Germany.
“The fast-growing market, good
prospects for the overall economy, the
central location, a good wastepaper sup-
ply and a shortage of domestic capacity
were the key reasons for Mondi’s invest-
ment,” explains Market Intelligence and
Research Manager Marcin Szwarc.

“I see Mondi Świecie emerging as the preferred
solutions provider for containerboard in Europe,”
says Maciej Kunda, CEO of Mondi Świecie SA.
MONDI ŚWIECIE ECO7
Economy meets ecology
Fast, light and central are the adjectives with which the Mondi Group describes
ECO7, its new Metso-supplied lightweight recycled containerboard line PM 7 in
Świecie, Poland. The line enables cost-effective and sustainable production with
no compromises on quality or performance.
TEXT Maiju Salenius and Marjaana Lehtinen PHOTOS courtesy of Mondi
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 
Maximum quality,
minimum environmental impact
In ECO7, economy has been designed to
meet ecology: maximum product quality
is achieved with minimum environmental
impact.
The recent investments have enabled
Mondi to minimize its carbon footprint
substantially. For example, CO
2
emissions
have been reduced by more than 100,000
tpy, in addition to the 400,000 tpy already
reduced earlier. Despite the increase in
paper production, this translates into a CO
2
emission reduction of over 60%.
Quality standards for recycled ber

ECO7’s furnish is 100% recycled fiber. When
the line reaches its full capacity, the total
recycled paper consumption will increase
to around 900,000 tons per year, equating
to over 40% of the wastepaper collected
in Poland.
“Mondi is by far the biggest buyer of
brown grades in Poland, so the sources of
our raw materials reflect the structure of
the country’s collection system. The paper
originates from industrial collection, retail
chains, corrugators and collection points
that buy material from individuals and
small enterprises,” says Marek Skorwider,
Purchasing Director, Recovered Paper.
According to OCC Manager Andrzej 
Błażejewicz, an analysis of the quality of the
recovered paper over several years has al-
lowed the mill to develop quality standards
for its raw materials purchases. Supplier
training has brought good results and
reduced problems during recovered paper
processing in the recycled fiber (RCF) line.
during the previous project also influenced
the decision in favor of Metso,” points out
Project Manager Maciej Janeczek, refer-
ring to a rebuild project in which Metso
converted Świecie’s sack paper machine
PM 1 for two-ply kraftliner.
“Mondi always seeks to cooperate with

partners capable of providing reliable and
proven services. This approach is especially
important for strategic investments,” he
continues.
With a design speed of 1,800 m/min and
a capacity of 470,000 tpy, the 8.6-meter-
wide PM 7 is one of the world’s fastest
containerboard machines. Its efficiency
“Our positive experience during the previous project also
influenced the decision in favor of Metso,” points out Project Manager
Maciej Janeczek (left), referring to a rebuild project in which Metso converted Świecie’s sack paper
machine PM 1 for two-ply kraftliner. Metso's Project Manager Juha Hentunen on the right.
One of the world’s fastest
containerboard machines
ECO7 represents a very large Metso de-
livery, extending from the RCF line to the
OptiConcept machine line. It also includes
a comprehensive automation package
with the latest and best-quality control and
diagnostic measurement technology.
“Metso was selected to deliver the
new line because they offered a techni-
cally advanced and proven concept at a
competitive price. Our positive experience
and short production cycles facilitate
shorter lead times as well as high and fast
availability of standard grades. The product
range encompasses lightweight recycled
fluting and testliner from 75 to 140 g/m
2

.
The maximum speed achieved so far on
100 g/m
2
fluting is 1,400 m/min.
Technological factors
hidden in all sections
“The key factor in the production of
lightweight fluting is an efficient paper
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 
A USEFUL TIP
Take full advantage of
the supplier’s experience
A new line, new technology – so many things to learn, not only by
new recruits but also by existing staff. It pays to take full advan-
tage of the supplier’s in-depth expertise and experience gained
from other deliveries. That’s what Mondi Świecie did in training
almost a hundred of its people working on ECO7.
“Approximately 60% constituted experienced people, in particu-
lar specialists and managers from other production departments
within the mill. A special training schedule was developed for each
new employee, together with training materials and an acclima-
tization package,” explains Jarosław Ożóg, Director of Human
Resources.
In addition, the new employees also received training by Metso,
as well as hands-on training. They also took part in the pre-start-up
inspection and system commissioning.
“The Metso people did a great job teaching and helping the
operators and maintenance staff to understand the machine. The

hands-on approach proved most successful, with our people work-
ing alongside the Metso team every day,” says PM 7 Production
Manager Piotr Kowalkiewicz. “It is much easier to learn from the ex-
perience of others than from your own mistakes. Routine problems
for the Metso people were new to the operators on site. In my opin-
ion, this approach enabled us to complete a good start-up phase
and gave us the opportunity to develop production efficiently.”
And he goes on: “The new line contains very modern and
automated equipment, which, in general, is easier to operate. The
extensive DNAhelp tool allows a much faster response in case
of problems. This is a high-speed paper machine, so everything
happens much faster – and the response to problems has to be
extremely quick. As one operator said, ‘This machine does not for-
give mistakes and negligence’, so it has to be treated with respect.
In general, working with ECO7 demands a lot of attention, but it
also gives a lot of satisfaction to all the maintenance and opera-
tions people.”
machine. The most important technologi-
cal factors are ‘hidden’ in every section
of the production line,” reveals PM 7 Line
Manager Robert Raniszewski.
For example, the stock preparation
system is designed to eliminate stickies
and has been optimized to guarantee
smooth production on the paper machine.
The OptiFormer forming section and the
SymPress B press section operate very reli-
ably, enabling the mill to reach its quality
targets.
In the SymRun pre-dryer section, single-

tier web guidance and a smoothly operat-
ing threading system provide for run-
nability. The advanced film transfer by the
OptiSizer size press completes the sheet
strength and helps to maintain good run-
nability. A double-tier group installed at
the end of the SymDry after-dryer section
contributes to good flatness properties.
Entire line capacity managed
with one single winder
OptiReel Plus reel enables the mill to pro-
duce jumbo reels with a weight of 100 tons
and a diameter of 4.6 meters. The produc-The produc-
tion capacity of 470,000 tpy is handled by
one single winder, the WinDrum Pro. The
robust and utmost reliable winder design
combines all the latest advanced winding
features, such as automatic splicing, knife
adjusting, set changing and core loading.
The whole production line is con-
trolled by a metsoDNA DCS/QCS system.
According to Raniszewski, it offers very reli-
able and helpful diagnostic tools that make
Marcin Szwarc Andrzej Błażejewicz Maciej Janeczek
Robert Raniszewski
    / 21
 
problem-solving much easier and faster
than with their other machines.
“The machine features the best available

technology and is designed to operate
with low water and energy consumption.
The machine concept is flexible and allows
optimization of the furnish composition
and other factors, depending on market
needs,” Janeczek adds.
A project can be fun
The amount of work during the installation,
testing and start-up phases of such a pro-
duction line is massive. Doing everything
right and on schedule calls for high staff
motivation and good cooperation with the
main supplier on site.
“The process was accomplished through
partnership and trust. For our people, this
project was ‘fun’ and a constant challenge,
so it was easy to sustain high motivation.
Metso also prepared a good team. That’s
the whole secret,” Raniszewski states.
“Commissioning was a very intensive
period for all the testing teams, including
Metso, Mondi and various contractors.
They all performed excellently,” adds PM 7
Production Manager Piotr Kowalkiewicz.
“Of course, we had good and bad days, but
we were always able to solve the problems
and push the process forward.”
The good feelings about the project are
mutual: Metso’s team also greatly enjoyed
cooperating with Mondi Świecie’s team.

Customers impressed by
runnability on corrugators
Production has been very promising in the
first months after the start-up and has ex-
ceeded the estimated volumes. And what’s
best, the feedback from the customers has
been extremely positive.
“We started to produce marketable
quality within a few days. The paper quality
was according to the standard accepted
by our customers. A series of tests on cor-
rugators also confirmed good runnability
and strength of board in view of ECT and
FCT. With the papers produced by ECO7,
our customers can run their corrugators
at maximum speed and efficiency,” says
Technical & Marketing Service Manager
Marek Motylewski.
“The most recent 4-month production
run has already exceeded our planned
start-up curve. Our new lightweight
recycled paper has been well received by
our customers. They are impressed by its
excellent runnability and other distinc-
tive characteristics, including consistent
technological parameters and profiles,
improved printability, and increased speed
and capacity.”
Juha Hentunen
Project Manager

Paper business line
Tel. +358 20 482 5030

Piotr Kowalkiewicz Marek Motylewski Jarosław Ożóg
After the intensive commissioning period, the first jumbo reel was produced on September 1, 2009.
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 
New TwinRoll Evolution cuts 
discharges and costs at Zellsto- 
und Papierfabrik Rosenthal
The pulp mill owned by Zellstoff- und Papierfabrik Rosenthal GmbH (ZPR)
located in Blankenstein an der Saale, Germany is proud to claim itself as
one of the most modern kraft pulp mills in Europe. The mill’s continuous
investment in the latest technology of the highest technical standard
available supports this contention.
TEXT David Wold
Early in 2009, ZPR launched a project to
improve brown-stock washing. Project goals
were numerous. Among them was the instal-
lation of two new wash presses to reduce
wastewater discharges into the Saale River
and to reduce the fees ZPR is obliged to pay
under German legislation for such discharges.
TwinRoll Evolution wash press
meets tough specications
Expectations for the wash presses also
included low maintenance requirements
and high availability, reduced consump-
tion of bleaching chemicals and enhanced
prospects for increasing the production

of bleached pulp from 328,000 to 400,000
ADT p.a. in the future.
To meet these tough specifications, ZPR
selected a new generation twin roll wash
press that Metso has dubbed the TwinRoll
Evolution for installation in its brown stock
fiber line, and a TwinRoll TRPBZ wash press
in the bleach plant.
While retaining the best features of
previous generations, the new TwinRoll
Evolution wash press significantly en-
hances performance. It does this through
a number of innovative design modifica-
tions that increase capacity by as much
as 30%.
“At ZPR technical staff play an important
part in making decisions regarding pur-
chases of new equipment. We are always
eager to get the latest technology with
the highest technical standard available,"
says Ado lf  Koppensteiner, Manager at
the mill.
“We are also very keen on
achieving high availability and
low maintenance requirements,
and we expect the TwinRoll
Evolution wash press will set a
new standard in this direction.”
Adolf Koppensteiner, Mill Manager, Rosenthal
GmbH (left) and Lars Dahlqvist, President, Metso

Paper Sundsvall AB, unveil the first TwinRoll
Evolution during a ceremony in Sundsvall.
Technical benets of the
brown-stock washing project
The new TwinRoll Evolution wash press is
installed between the knotter and an older
TwinRoll wash press positioned before the
oxygen stage. The TwinRoll TRPBZ wash
press is installed before the Z-stage in the
bleach plant. This configuration permit-
ted removal of the peroxide stage in the
bleach plant. See Figure 1 and Figure 2.
The technical benefits of this project
include additional closing of the filtrate
loops, cleaner pulp into the ozone stage,
better temperature control of the pulp
into the Z-stage in the TCF sequence.
Furthermore, it also enables operating in
the future without ozone in the ECF-bleach
sequence.
“The TwinRoll Evolution press worked
as planned during start-up. Though there
were some small hiccups, the start-up
of this new machine actually went even
better than expected. There were no
unplanned stoppages. The rst TwinRoll Evolution in operation at Rosenthal GmbH, Germany.
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 
“In terms of performance, the press easily
achieves the mill’s targeted production

level of 1,050 t/d, and not once during trial
operation was the outgoing pulp concen-
tration below the 32% level stipulated in
the contract,” says Koppensteiner.
Cost savings
The reduction in fees ZPR is obliged to
pay for discharges into the river under
German legislation is a major cost saving.
Recirculation of PO filtrate to the OP stage
cuts peroxide consumption. Recirculated
PO filtrate increases the pH value before
the OP stage to reduce caustic soda con-
sumption.
The additional washing equipment in the
brown-stock fiber line has made it possible
to reduce the dilution factor. As a result the
dry solids content of the weak black liquor
has increased and the low-pressure steam
consumption for evaporation has been
reduced. Replacing the old ozone stage
fluffer with a new plug shredder and remov-
ing the final P-stage up-stream towers has
reduced energy consumption. Removing
old equipment in the bleach plant also
saves maintenance expenses.
“The annual cost savings from the
washer project are considerable. The
capital expenditure is low and the payback
time is expected to be less than two years,”
Koppensteiner emphasizes.

Development for the better
By definition, evolution means developing
into something better, and this is exactly
what the TwinRoll Evolution press repre-
sents. Although this new generation wash
press employs many of the same compo-
nents as previous twin roll presses, such
as a modular design to simplify the design
structure and help cut delivery times, this
generation performs even better.
The principal benefit of the TwinRoll
Evolution press is its significantly greater
capacity over a wider feed consistency
range, compared with previous presses.
At the same time, the TwinRoll Evolution
delivers greater washing efficiency, main-
tained at higher capacities.
Modularization also positively affects
maintenance costs. When there are several
TwinRoll presses in the mill, the quantity of
spare parts to be stocked is reduced sig-
nificantly. The rolls are the same as those
used on the fourth generation TwinRoll
presses.
“After this modernization, we will
have a total of six TwinRoll presses in
our mill. Of course, being able to stock
interchangeable spare parts was an
important consideration when we chose
the TwinRoll Evolution press. The press

also offers a high degree of safety for staff,
a wide capacity range, and automated
systems for optimum operation,” says
Koppensteiner.

New equipment
Demontage
Relocated
P P
D
PO
Q
BT
HD
5000 m
3
z
Q
HD
Q
1200 m
3
O2
I
O2
II
BT
DIG
HD
4000 m

3
OP
BT
New equipment
Relocated
D
PO
Q
BT
HD
5000 m
3
z
Q
HD
Q
1200 m
3
O2
I
O2
II
BT
DIG
HD
4000 m
3
OP
BT
Magnus Danielsson

Manager, Machine Design
and Product Manager Washing
Fiber business line
Tel. +46 60 16 55 36

n New equipment
n Dismantling
n Relocated
n New equipment
n Relocated
Figure 1. Investments to
offset effluent charges.
Figure 2. New fiber line after rebuild.
24 /    
 
HiRun runnability blow boxes are used for
improving sheet support at the single-tier
dryer groups of high-speed paper and
board machines. The latest HiRun blow
box design includes features that improve
performance and decrease energy con-
sumption. Now some of these technical
improvements are also available as an easy
upgrade package for existing HiRun blow
boxes. This HiRun upgrade service can be
carried out at the customer’s mill concur-
rently with regular blow box overhaul.
Fast upgrade during
maintenance shutdown
Stora Enso Sachsen Papier PM 1 in

Germany produces newsprint with a wire
width of 10 m and a production speed of
1,750 m/min. The mill was among the first
in adopting HiRun technology in 2003. A
total of seven HiRun blow boxes placed at
the start of the dryer section are currently
HiRun upgrade service saves 
energy at Sachsen PM 1
TEXT Paavo Sairanen
“The performance of Metso’s service team
was very professional and the improvement
achieved in energy efficiency is of great
importance to our mill,”
says Uwe Commichau, Mechanical Maintenance Manager, Sachsen Papier.
Air ow reduction
provides remarkable
savings in fan power need.
100 90 80 70 60 50 40 30 20 10 0
Air flow, %
Fan power, %
Needed fan power vs. airflow with speed (frequency) controlled motors
100
80
60
40
20
0
ensuring the runnability of the machine’s
newsprint production.
All HiRun blow boxes were upgraded at

the mill’s annual maintenance shutdown
in December 2009. In addition to gen-
eral maintenance and upkeep, the target
was to save electric energy. The scope of
service included an upgrade of the blow
box edge areas as well as a complete
box overhaul (including replacement of
coanda profiles and labyrinth seals). The
end covers were replaced with new ones
in this upgrade, including an improved
end sealing arrangement. These new end
covers also include a service hatch at the
tending side that enables faster and easier
VacRoll cleaning.
50% energy savings
The improved end sealing arrangement
reduces air consumption, thus creating
savings in air fan electricity use. Fan power
HiRun blow box before and after upgrade.
Paavo Sairanen
Global Product Manager
Air Systems Service
Tel. +358 50 317 3873

Before
After
consumption was reduced by nearly 50%
after final setup while blow box perform-
ance remained at the same level as before
the HiRun upgrade service.

This upgrade service is available for all
HiRun blow box models. The redesigned
blow box construction is a standard fea-
ture for new HiRun blow boxes.
    / 25
  
New generation blow boxes
for improved runnability
and electricity savings
Most of the severe runnability problems
at the dryer section are caused by the fact
that wet paper has tendency to stick to
the hot dryer cylinder surface. This is due
to adhesion forces and aerodynamics in
the opening nip. These forces are increas-
ing with machine speed. By directing the
counter forces with blow boxes to just the
right zones in the pocket area, it is possible
to improve the runnability.
Also, energy aspects have been carefully
taken into account when improving our
runnability systems. One example of this is
the development of the SymRun Plus blow
box, which replaced the previous SymRun
HS model. This improvement leads to
about 50% lower electricity consump-
tion due to the smaller air flows and other
modifications in the blow box design.
The same type of improvement has
recently been carried out on the HiRun

runnability system. With certain construc-
tional modifications to HiRun blow boxes,
the energy usage of the system can be
reduced by about 30%. In addition to this,
an even bigger reduction in the fan energy
usage has been possible with our newest
HiRun blow box model – and without
compromising sheet runnability or tail
threading efficiency. This state-of-the-art
design uses 40% less electricity to create
the same supporting force for the paper
sheet against the dryer fabric than the
previous model.
These remarkable results (Figure 1) in
energy savings have been possible by re-
thinking the equipment construction and
carefully researching the paper web behav-
iour, especially in the opening dryer nip.
Additional energy savings with
new ways to run the air system
In addition to the above savings given by
new energy-friendly equipment, it is also
possible to re-think the ways of running
the whole air system. By controlling the
air systems in a new way, it is possible to
achieve big energy savings in the dryer
section runnability . This kind of adjustment
can be done both for runnability boxes and
for vacuum rolls in the dryer section.
For the VacRoll system, for example, this

kind of optimizing process means that the
ductwork is designed so that the system
can be divided into separate vacuum
zones in the machine direction. Generally,
at least two VacRoll fans with variable
speed drives are needed for the system in
order to be able to minimize the energy
consumption in a proper way.
With such main arrangements in the air
system, it is now possible to optimize the
vacuum levels in the machine direction so
that sheet runnability remains excellent but
fan energy usage is lowered dramatically.
The highest vacuums are needed at the
beginning of the dryer section, where the
sheet is weakest. When going towards the
dry end of the dryer section, the vacuums
can be reduced without causing any harm
to the sheet. This enables less fan power to
be used in the latter part of the dryer section.
Of course, the possibility to carry out
this kind of adjustment successfully also
depends on the paper grade and produc-
tion speed. But even quite small reductions
in air flows are known to be very beneficial
in the energy respect if the adjusting is
done by using variable speed drives for the
fan motors. The dimensioned full air flows
and fan power are, however, normally
needed for successful tail threading.

Figure 2 schematically shows the principle
of this new way of running the runnability
air system with optimized air flows in the
machine direction. By adjusting the VacRoll air
flows accordingly it is possible to achieve even
50% savings in fan power consumption.

Pekka Saarikivi
Product Manager, Air systems
Tel. +358 20 482 4352

New ways to run with less energy
TEXT Heli Anttila and Pekka Saarikivi
Development towards more sustainable paper production is a continuous process. An
important part of this development is the overall tendency to reduce the drying section
energy usage. Several improvements have recently led to new and more energy-efficient
runnability systems at the dryer section. And what is also important is that, in spite of the
lower energy usage, the performance of the new runnability systems is even better than
before, resulting in higher productivity from the papermaking line.
Figure 2. Principle of the optimized way to run the dryer section air system.
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SymRun HS
SymRun Plus
HiRun
New HiRun

Energy consumption, %
Figure 1. Positive results of the recent
development projects for SymRun Plus
and the newest HiRun blow boxes.
Vacuum level