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Varel

  • HEIDENHEIM and VAREL, Germany , Aug. 14, 2019 (Press Release) -
  • IIoT platform OnCumulus the basis for fast, reliable and secure access to all machine and production data.
  • Dewatering module and Tandem NipcoFlex press increase dry content by 1 percent
  • 15 percent increase in total output planned

The ongoing development of its products is just as much an integral part of the corporate philosophy of paper and board manufacturer Papier- und Kartonfabrik Varel (PKV) as the constant improvement of production efficiency. To achieve these goals the company, which was established in 1938, has been working with Voith for many years. For its current rebuild of the PM 4, PKV is also relying on the expertise of the technology group from Heidenheim.

On the PM 4, PKV produces packaging papers with a wide range of basis weights from 120 to 280 grams per square meter. Previously, the web width on the pope roller was 5,250 mm. As part of the rebuild, the width will be increased to 5,450 mm. The new width necessitates various adjustments to upstream components. Voith team will increase the widths of the first dryer group, the existing headboxes, the wire and press sections and the Fourdrinier wire.

The key items on PKV’s agenda were increasing the total output by 15 percent, improving runability and reducing specific energy costs. In addition, optimizing the dewatering capacity is intended to raise the dry content downstream of the Tandem NipcoFlex press by at least one percent.

IIoT platform OnCumulus: pivotal to digitalization

An essential prerequisite to achieving the desired effects was the integration of the latest Papermaking 4.0 technologies. In this context, the IIoT platform OnCumulus is absolute crucial, as it enables fast, reliable and secure access to data from local machines and systems in the cloud and makes them available for efficient use. Other modules from the Voith OnEfficiency product family like OnEfficiency.Strength or OnEfficiency.Dewatering are used to monitor paper production at PKV. All modules and components are networked with one another. The PKV team also has transparent access to all relevant data at any time.

Fewer strength fluctuations

OnEfficiency.Strength uses statistical models and virtual sensors to reduce strength fluctuations in machine direction. As a result fiber use and starch use are optimized. Continuous measurements and automatic adjustments to parameters ensure fewer fluctuations, which in turn minimizes broke, reduces deviations in production output and improves paper quality during grade changes.

Stable dry content

By means of systematic regulation of the former vacuum the OnEfficiency.Dewatering module stabilizes the dry content upstream of the press. This helps to save energy, while the Papermaking 4.0 technology ensures consistently high ply bond strength.

To ensure the requested one percent improvement in dry content, Voith installed a Tandem NipcoFlex system designed in this case for web widths of up to 5,700 mm. Its innovative design allows optimum dewatering for the entire basis weight range of the PM 4. As a result, PKV can further improve the strength and surface quality of its corrugated baseboard made from secondary and virgin fibers. A closed web run in combination with separation suction boxes allows production speeds of up to 1,200 m/minute and is therefore the main basis for the substantial increase in production capacity requested by customer.

Initial clothing of PM 4 by Voith

To achieve the required dry contents, it is important that the clothing is perfectly matched over the entire paper machine. From the outset, the PM 4 will be fitted with I-Series forming wires, Infinity press felts and MultiTech dryer fabrics.

More uniform CD profile

In addition, the existing ModuleJet II headbox system in the backliner headbox will be extended by adding an OnQ Profilmatic CD profile control. OnQ Profilmatic can determine the proportion of random noise in the measurements. Its continuous dynamic profile mapping allows exact local assignment of the actuator control zones to the measured values. This results in more uniform CD profiles and therefore improved paper quality. On the Fourdrinier wire, the extensively proven HiVac high vacuum suction box will replace the previously used couch roll. The vacuum system helps reduce the paper machine’s energy consumption and increases the dry content of the paper web.

Saving resources in the white top and achieving optimum paper edge

EdgeExpert returns the white paper fibers to the appropriate system, ensuring that these fibers are preserved for use in the white top. EdgeDeckle S is the latest tool for controlling the edge in the wire section. It ensures a good paper edge with optimum profile quality.

Efficient cleaning systems for greater runability

The installation of cutting-edge cleaning systems like CleanLine Excell or ProLub improves runability and increases the total output of the PM 4. The permeability of the Voith clothing is maintained for longer, which results in a more homogeneous paper web. In addition, CleanLine Excell needs much less water than high-pressure showers and cleans so effectively that the use of chemical cleaners is much reduced or dispensed with altogether.

Safer reel change

The EcoChange W reel changing system, which works with traversing high-pressure water jet nozzles, is another component which has enabled Voith to achieve PKV’s specified goals like an increase in total output and improvement in the runability of the PM 4. The system enables efficient changing of the paper rolls and will be integrated as part of the adjustment of the Pope roller’s web width, resulting in minimal broke during reel changes.

In addition, Voith’s scope of supply also includes upgrading the air systems, adapting the dryer hood and drive technology, and automating the paper machine. In this context, the Voith team was also able to contribute its expertise in detail engineering and is supporting PKV with the approval of the plant in accordance with the German Federal Immission Control Act.

About the Voith Group

The Voith Group is a global technology company. With its broad portfolio of systems, products, services and digital applications, Voith sets standards in the markets of energy, oil & gas, paper, raw materials and transport & automotive. Founded in 1867, the company today has more than 19,000 employees, sales of € 4.2 billion and locations in over 60 countries worldwide and is thus one of the larger family-owned companies in Europe.

About Voith Paper

The Group Division Voith Paper is part of the Voith Group. As the full-line supplier to the paper industry, it provides the largest range of technologies, services, components and products on the market and offers paper manufacturers solutions from one single source. The company’s continuous stream of innovations takes papermaking to the next level and facilitates resource-conserving production. With its Servolution concept, Voith offers its customers tailored service solutions for all sections of the production process. Voith Papermaking 4.0 ensures that equipment is optimally connected, while the secure use of generated data enables paper manufacturers to improve plant availability and efficiency.

Voith to supply its Papermaking 4.0 technologies for Papier- und Kartonfabrik Varel's PM 4 rebuild at its site in Varel, Germany

Posted in: Mills 08/21/2019 - 05:16
  • HEIDENHEIM and VAREL, Germany , Aug. 14, 2019 (Press Release) -
  • IIoT platform OnCumulus the basis for fast, reliable and secure access to all machine and production data.
  • Dewatering module and Tandem NipcoFlex press increase dry content by 1 percent
  • 15 percent increase in total output planned

The ongoing development of its products is just as much an integral part of the corporate philosophy of paper and board manufacturer Papier- und Kartonfabrik Varel (PKV) as the constant improvement of production efficiency. To achieve these goals the company, which was established in 1938, has been working with Voith for many years. For its current rebuild of the PM 4, PKV is also relying on the expertise of the technology group from Heidenheim.

On the PM 4, PKV produces packaging papers with a wide range of basis weights from 120 to 280 grams per square meter. Previously, the web width on the pope roller was 5,250 mm. As part of the rebuild, the width will be increased to 5,450 mm. The new width necessitates various adjustments to upstream components. Voith team will increase the widths of the first dryer group, the existing headboxes, the wire and press sections and the Fourdrinier wire.

The key items on PKV’s agenda were increasing the total output by 15 percent, improving runability and reducing specific energy costs. In addition, optimizing the dewatering capacity is intended to raise the dry content downstream of the Tandem NipcoFlex press by at least one percent.

IIoT platform OnCumulus: pivotal to digitalization

An essential prerequisite to achieving the desired effects was the integration of the latest Papermaking 4.0 technologies. In this context, the IIoT platform OnCumulus is absolute crucial, as it enables fast, reliable and secure access to data from local machines and systems in the cloud and makes them available for efficient use. Other modules from the Voith OnEfficiency product family like OnEfficiency.Strength or OnEfficiency.Dewatering are used to monitor paper production at PKV. All modules and components are networked with one another. The PKV team also has transparent access to all relevant data at any time.

Fewer strength fluctuations

OnEfficiency.Strength uses statistical models and virtual sensors to reduce strength fluctuations in machine direction. As a result fiber use and starch use are optimized. Continuous measurements and automatic adjustments to parameters ensure fewer fluctuations, which in turn minimizes broke, reduces deviations in production output and improves paper quality during grade changes.

Stable dry content

By means of systematic regulation of the former vacuum the OnEfficiency.Dewatering module stabilizes the dry content upstream of the press. This helps to save energy, while the Papermaking 4.0 technology ensures consistently high ply bond strength.

To ensure the requested one percent improvement in dry content, Voith installed a Tandem NipcoFlex system designed in this case for web widths of up to 5,700 mm. Its innovative design allows optimum dewatering for the entire basis weight range of the PM 4. As a result, PKV can further improve the strength and surface quality of its corrugated baseboard made from secondary and virgin fibers. A closed web run in combination with separation suction boxes allows production speeds of up to 1,200 m/minute and is therefore the main basis for the substantial increase in production capacity requested by customer.

Initial clothing of PM 4 by Voith

To achieve the required dry contents, it is important that the clothing is perfectly matched over the entire paper machine. From the outset, the PM 4 will be fitted with I-Series forming wires, Infinity press felts and MultiTech dryer fabrics.

More uniform CD profile

In addition, the existing ModuleJet II headbox system in the backliner headbox will be extended by adding an OnQ Profilmatic CD profile control. OnQ Profilmatic can determine the proportion of random noise in the measurements. Its continuous dynamic profile mapping allows exact local assignment of the actuator control zones to the measured values. This results in more uniform CD profiles and therefore improved paper quality. On the Fourdrinier wire, the extensively proven HiVac high vacuum suction box will replace the previously used couch roll. The vacuum system helps reduce the paper machine’s energy consumption and increases the dry content of the paper web.

Saving resources in the white top and achieving optimum paper edge

EdgeExpert returns the white paper fibers to the appropriate system, ensuring that these fibers are preserved for use in the white top. EdgeDeckle S is the latest tool for controlling the edge in the wire section. It ensures a good paper edge with optimum profile quality.

Efficient cleaning systems for greater runability

The installation of cutting-edge cleaning systems like CleanLine Excell or ProLub improves runability and increases the total output of the PM 4. The permeability of the Voith clothing is maintained for longer, which results in a more homogeneous paper web. In addition, CleanLine Excell needs much less water than high-pressure showers and cleans so effectively that the use of chemical cleaners is much reduced or dispensed with altogether.

Safer reel change

The EcoChange W reel changing system, which works with traversing high-pressure water jet nozzles, is another component which has enabled Voith to achieve PKV’s specified goals like an increase in total output and improvement in the runability of the PM 4. The system enables efficient changing of the paper rolls and will be integrated as part of the adjustment of the Pope roller’s web width, resulting in minimal broke during reel changes.

In addition, Voith’s scope of supply also includes upgrading the air systems, adapting the dryer hood and drive technology, and automating the paper machine. In this context, the Voith team was also able to contribute its expertise in detail engineering and is supporting PKV with the approval of the plant in accordance with the German Federal Immission Control Act.

About the Voith Group

The Voith Group is a global technology company. With its broad portfolio of systems, products, services and digital applications, Voith sets standards in the markets of energy, oil & gas, paper, raw materials and transport & automotive. Founded in 1867, the company today has more than 19,000 employees, sales of € 4.2 billion and locations in over 60 countries worldwide and is thus one of the larger family-owned companies in Europe.

About Voith Paper

The Group Division Voith Paper is part of the Voith Group. As the full-line supplier to the paper industry, it provides the largest range of technologies, services, components and products on the market and offers paper manufacturers solutions from one single source. The company’s continuous stream of innovations takes papermaking to the next level and facilitates resource-conserving production. With its Servolution concept, Voith offers its customers tailored service solutions for all sections of the production process. Voith Papermaking 4.0 ensures that equipment is optimally connected, while the secure use of generated data enables paper manufacturers to improve plant availability and efficiency.

Read more

VAREL, Germany , Nov. 21, 2018 (Press Release) -As public holidays during the end of the year 2018 are challenging for logistic reasons (limited transport-/warehouse capacity as well as limited number of loading days), VAREL is going to take downtime on all four machines (Containerboard + Cartonboard) during Xmas and the turn of the year. Furthermore already end of last year projected maintenance services for 2018 have to be completed during these days without production.

Due to serve our clients with paper and board as early as possible in 2019, the „machine by machine“-restart is scheduled for January 2nd.

We will curtail our capacity in total by approx. 14.000 t (8.000 t of Containerboard | 6.000 t of Cartonboard)“

Germany’s Varel to take downtime on all four machines during Christmas period

11/21/2018 - 01:16

VAREL, Germany , Nov. 21, 2018 (Press Release) -As public holidays during the end of the year 2018 are challenging for logistic reasons (limited transport-/warehouse capacity as well as limited number of loading days), VAREL is going to take downtime on all four machines (Containerboard + Cartonboard) during Xmas and the turn of the year. Furthermore already end of last year projected maintenance services for 2018 have to be completed during these days without production.

Due to serve our clients with paper and board as early as possible in 2019, the „machine by machine“-restart is scheduled for January 2nd.

We will curtail our capacity in total by approx. 14.000 t (8.000 t of Containerboard | 6.000 t of Cartonboard)“

Read more

VAREL, Germany, March 12, 2012 (Press Release) -

The association "Jever Aktiv" and trade council of Friesland, Wittmund and the town of Wilhelmshaven honored companies with outstanding achievements on annual basis, one of them Papier- und Kartonfabrik Varel for 2011. Special focus was laid on field of education and environmental protection as well as support of cultural and social projects.

During the gala event presenter Mr. Martin Steinbrecher congratulated as follows: "It is very good to have the Varel paper tigers. This family-owned company is very well prepared for future challenges. The mill with its own power plant is a light house of energy-efficiency in Europe. 450 employees, among them 36 trainees, produce paper and board products based on 100% recycled fibres for customers worldwide, since 70 years." (source: Friebo edition 06/2012).

The official certificate and the trophy "Molenfeuer" were gratefully received by our shareholders Jürgen and Kristian Evers as well as general managers Horst Büsing, Klaus Schnitger and Uwe Wollschläger.

The award is an incentive and motivation, to continue our corporate policy of ecofriendly and innovative action, to provide positive contribution in shaping our future.

By Gertrude and Hellmut Barthel Foundation also considerable amounts of money for environmental projects and the promotion of culture in the region are provided.

Germany's Papier- und Kartonfabrik Varel awarded for outstanding achievements by Jever Aktiv and trade council of Friesland

Posted in: Environment 03/11/2012 - 21:26

VAREL, Germany, March 12, 2012 (Press Release) -

The association "Jever Aktiv" and trade council of Friesland, Wittmund and the town of Wilhelmshaven honored companies with outstanding achievements on annual basis, one of them Papier- und Kartonfabrik Varel for 2011. Special focus was laid on field of education and environmental protection as well as support of cultural and social projects.

During the gala event presenter Mr. Martin Steinbrecher congratulated as follows: "It is very good to have the Varel paper tigers. This family-owned company is very well prepared for future challenges. The mill with its own power plant is a light house of energy-efficiency in Europe. 450 employees, among them 36 trainees, produce paper and board products based on 100% recycled fibres for customers worldwide, since 70 years." (source: Friebo edition 06/2012).

The official certificate and the trophy "Molenfeuer" were gratefully received by our shareholders Jürgen and Kristian Evers as well as general managers Horst Büsing, Klaus Schnitger and Uwe Wollschläger.

The award is an incentive and motivation, to continue our corporate policy of ecofriendly and innovative action, to provide positive contribution in shaping our future.

By Gertrude and Hellmut Barthel Foundation also considerable amounts of money for environmental projects and the promotion of culture in the region are provided.

Read more

VAREL, Germany, Jan. 16, 2012 (Press Release) -Expansion of combined heat and power at the paper and cardboard factory Varel

With the commissioning of the steam turbine 9, the efficiency of energy production in paper and board mill Varel has been further increased. The steam turbine 9 has an output of 13.9 MW and the steam turbine power generation takes over the 1 and 2 These were taken from the regular operations, but are still available as reserve capacity.

The steam is at 480 ° C and 80 bar led to the turbine and exits at 170 ° C and 6 bar. Compared with the previous steam turbine, the efficiency could be increased by 25%, which contributes to a significant reduction in specific CO2 emissions.

The turbine itself weighs 25 tons, to the generator comes with 45t. Together with the gear and the other units, the total system weighs about 100 tons. The integration of such a complex system into an existing combined heat and power plant is also a major logistical challenge, the team the power plant the paper and cardboard factory Varel and those involved in the installation companies have passed with flying colors.

The continued investment in environmentally friendly and future-oriented energy shows once more that the protection of the environment for the paper and cardboard factory Varel has a great importance.

Germany's Papier- und Kartonfabrik Varel expands its energy production

Posted in: Bio-Insight 01/15/2012 - 18:12

VAREL, Germany, Jan. 16, 2012 (Press Release) -Expansion of combined heat and power at the paper and cardboard factory Varel

With the commissioning of the steam turbine 9, the efficiency of energy production in paper and board mill Varel has been further increased. The steam turbine 9 has an output of 13.9 MW and the steam turbine power generation takes over the 1 and 2 These were taken from the regular operations, but are still available as reserve capacity.

The steam is at 480 ° C and 80 bar led to the turbine and exits at 170 ° C and 6 bar. Compared with the previous steam turbine, the efficiency could be increased by 25%, which contributes to a significant reduction in specific CO2 emissions.

The turbine itself weighs 25 tons, to the generator comes with 45t. Together with the gear and the other units, the total system weighs about 100 tons. The integration of such a complex system into an existing combined heat and power plant is also a major logistical challenge, the team the power plant the paper and cardboard factory Varel and those involved in the installation companies have passed with flying colors.

The continued investment in environmentally friendly and future-oriented energy shows once more that the protection of the environment for the paper and cardboard factory Varel has a great importance.

Read more

VAREL, Germany, March 24, 2011 (Press Release) -With great commitment we push forward with the revamp of paper machine no. 4. The reconstruction of our PM 4 to enlarge the product portfolio by white testliner and kraftliner substitute qualities is a great challenge.

Some new installed components of the PM 4 are already put into operation or start-up is planned within short time. We would like to point out the following milestones:

Starch preparation plant:With this new device we activate starch enzymatically. This process is more eco-friendly, since the usage of chemical substances is not necessary. Also cumulative energy balance is significantly better in comparison to thermo-chemical method. Our new starch preparation plant is in operation since beginning of this year.

Indoor-crane:A new crane with a lift capacity of 80t is already installed since several weeks. This crane will lift all components to their final positon during the time of revamp from the beginning of April. Thereafter this crane will be used for tambour lifts as well as for maintenance jobs.

Pulper:A newly designed 90 m³ D-pulper is set on duty end of April. This unit is used for pulp supply of PM 4-line 1.

All revamp measures are carried out during the regular manufacturing schedule, which underlines the complexity of this project and capability of project teams to handle their duties properly. Prospect of extension of our high quality corrugating paper products by white testliners and kraftliner substitutes is motivation and commitment for all of us

Revamp of Varel's PM 4 in Germany progresses, will add white testliner and kraftliner substitutes to product portfolio

03/23/2011 - 23:51

VAREL, Germany, March 24, 2011 (Press Release) -With great commitment we push forward with the revamp of paper machine no. 4. The reconstruction of our PM 4 to enlarge the product portfolio by white testliner and kraftliner substitute qualities is a great challenge.

Some new installed components of the PM 4 are already put into operation or start-up is planned within short time. We would like to point out the following milestones:

Starch preparation plant:With this new device we activate starch enzymatically. This process is more eco-friendly, since the usage of chemical substances is not necessary. Also cumulative energy balance is significantly better in comparison to thermo-chemical method. Our new starch preparation plant is in operation since beginning of this year.

Indoor-crane:A new crane with a lift capacity of 80t is already installed since several weeks. This crane will lift all components to their final positon during the time of revamp from the beginning of April. Thereafter this crane will be used for tambour lifts as well as for maintenance jobs.

Pulper:A newly designed 90 m³ D-pulper is set on duty end of April. This unit is used for pulp supply of PM 4-line 1.

All revamp measures are carried out during the regular manufacturing schedule, which underlines the complexity of this project and capability of project teams to handle their duties properly. Prospect of extension of our high quality corrugating paper products by white testliners and kraftliner substitutes is motivation and commitment for all of us

Read more

VAREL, Germany, June 29, 2010 (Press Release) -As a further step towards more independence in energy supplies Papier- und Kartonfabrik Varel group currently installs a photovoltaic solar plant on roofs of warehouses no. 5 and 6.

The technical capacity of this solar plant is 998 kWp, installed on a surface of approx. 18.000 square metre. Within next weeks approx. 8.300 photovoltaic-modules manufactured by Inventux will be installed in row-parallel position.

By operating our solar plant we could save about 750.000 kg CO2 per year. This is equivalent to 6.250.000 km motorway-drive with a car, which has a standardised CO2 emission of 120 g per km.

This latest project is another contribution to enlarge share of renewable energy within our companies energy mix. Two biogas engines with 1 MW electrical output each, which are fueled exclusively with biogas from our water purification plant, have already been installed in 2006.

Varel installs solar plant on warehouse roofs to enlarge share of renewable energy

Posted in: Bio-Insight 06/29/2010 - 03:39

VAREL, Germany, June 29, 2010 (Press Release) -As a further step towards more independence in energy supplies Papier- und Kartonfabrik Varel group currently installs a photovoltaic solar plant on roofs of warehouses no. 5 and 6.

The technical capacity of this solar plant is 998 kWp, installed on a surface of approx. 18.000 square metre. Within next weeks approx. 8.300 photovoltaic-modules manufactured by Inventux will be installed in row-parallel position.

By operating our solar plant we could save about 750.000 kg CO2 per year. This is equivalent to 6.250.000 km motorway-drive with a car, which has a standardised CO2 emission of 120 g per km.

This latest project is another contribution to enlarge share of renewable energy within our companies energy mix. Two biogas engines with 1 MW electrical output each, which are fueled exclusively with biogas from our water purification plant, have already been installed in 2006.

Read more

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