Operational Excellence SStSuccess Story - TAPPI ppt.pdf · Operational Excellence SStSuccess Story...
Transcript of Operational Excellence SStSuccess Story - TAPPI ppt.pdf · Operational Excellence SStSuccess Story...
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Operational ExcellenceS StSuccess Story
PMT“The right Shoe Press”
Valter Canelli
PaperCon 2011 Page 1552
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• Fine Paper• Wire 148 inMill Overview• Speed 1970fpm
• Pap. De Clairefontaine #5
630 pli 400 pli
PaperCon 2011 Page 1553
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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
PaperCon 2011 Page 1554
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Mill Targets
before
ProductionSmoothness
Reel speed
Thickness
g/m2 ft/min milsSmoothnessTwo sidednessBulk
Laser print 100 1475 4.1
Notebooks 90 1640 ?
Copy color 80 1675 4.3Flexibility
Copy color 80 1675 4.3
Envelope 90 1525 4.8
Envelope 120 1245 6.3 - 6.6
Offset 200 690 ?
New grade 270 na na
PaperCon 2011 Page 1555
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Problem Description
• To justify a Shoe Press InvestmentTo justify a Shoe Press Investment
PaperCon 2011 Page 1556
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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
PaperCon 2011 Page 1557
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Problem DescriptionPRESS INFLUENCE
• 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
PaperCon 2011 Page 1558
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Problem Description
• Main Paper Properties
Important for NOT-printed Packaging Grades
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
PaperCon 2011 Page 1559
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Problem Description
• Main Paper Properties
Important for Writing & Printing Grades
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
PaperCon 2011 Page 1560
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Problem Description
• General Shoe Press Advantages:
+ Dryness
+ Bulk
+ Paper Strength+ Paper Strength
PaperCon 2011 Page 1561
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Problem Description
• Shoe Press Issues:
Investment Cost (ROI)
Impact on Paper Quality
PaperCon 2011 Page 1562
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Problem Description
• Why is it difficult to justify the Shoe Press investment?:
Weight Issues Existing Crane Limits Building Loads Limits
Dimensions Issues CD Interchange ability Diameter
Rebuild Down Time
PaperCon 2011 Page 1563
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Problem Description
• Why is it difficult to justify the Shoe Press investment?:
Felt Marking Issue
Roughness Two-Sidedness Issue
PaperCon 2011 Page 1564
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Solution Strategy
Long NIP Residence Time +++ Felt MarkingNIP Specific Pressure + Felt MarkingNIP Specific Pressure + Felt Marking
A Shoe Press with a Shorter Shoe
PaperCon 2011 Page 1565
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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 Page 1566
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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 Dryness
PaperCon 2011 Page 1567
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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 Dryness Marking
PaperCon 2011 Page 1568
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Solution Strategy
16
• Machine Direction NIP Profile
101214
re (M
Pa)
468
10
ic p
ress
ur
024
Spec
if
0 50 100 150 200 250 300 350Nip Length (mm)
250 mm shoe Dryness Marking
PaperCon 2011 Page 1569
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Solution Strategy
16
• Machine Direction NIP Profile
101214
e (M
Pa)
68
10
ic p
ress
ure
024
Spec
ifi
0 50 100 150 200 250 300 350Nip Length (mm)
250 mm shoe Dryness Marking
PaperCon 2011 Page 1570
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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)
250 mm shoe Dryness Marking
PaperCon 2011 Page 1571
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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)
250 mm shoe Dryness Marking
PaperCon 2011 Page 1572
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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
PaperCon 2011 Page 1573
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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
PaperCon 2011 Page 1574
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Solution Strategy
PaperCon 2011 Page 1575
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Implementation
• Pilot Hand Sheet Trials
Wet Sample
PaperCon 2011 Page 1576
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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
PaperCon 2011 Page 1577
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Implementation
• before
630 pli 400 pli
PaperCon 2011 Page 1578
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Implementation
• after
1030 pli 400 pli
SMARNIP® US patent 7811419
PaperCon 2011 Page 1579
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Success
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
PaperCon 2011 Page 1580
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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
PaperCon 2011 Page 1581
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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
PaperCon 2011 Page 1582
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Success
+ 10% Production increase
- 6% Steam Consumptionp
+ Bulk
+ Flexibility
PaperCon 2011 Page 1583
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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
PaperCon 2011 Page 1584
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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
PaperCon 2011 Page 1585
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• Fine Paper• Wire 158 inMill Overview• Speed 3610fpm
• Pap. De Clairefontaine #6
PaperCon 2011 Page 1586
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Implementation
1710 pli
PaperCon 2011 Page 1587
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Success
+ 20% Speed increase
+ Smoothness
+ Bulk 2.5% less raw material for same paper caliper
PaperCon 2011 Page 1588
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Success
PaperCon 2011 Page 1589
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Success
• Sizes: 28 – 30 – 44 in
PaperCon 2011 Page 1590
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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
PaperCon 2011 Page 1591
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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
PaperCon 2011 Page 1592