Varel, Germany, has started up its rebuilt PM 4 containerboard machine. The goals of the rebuild, conducted by Voith Paper, Germany, were to increase production capacity and expand the range of products on PM 4, as well as improve energy efficiency and overall environmental friendliness.
PM 4 produces corrugated media and test liners with a basis weight range of 120 to 220 gsm. In the future, up to 50% of its capacity should consist of white test liner. PM 4 is designed for a net cut working width of 5,100 mm and an annual capacity of 300,000 metric tons.
Due to the raw materials that will now be required, the rebuild included a significant expansion of the stock preparation systems on three lines, for which Voith provided the essential equipment. The paper mill received new approach flow systems, the headboxes were renewed, and both fourdriniers were extended. A DuoFormer D hybrid former was installed on the back ply, while the top ply received a DuoShake shaker unit. The dryer was completely renewed and a SpeedSizer film press with contact-free web drying was integrated. In addition, PM 4 received a soft calender and MasterReel rewinder. A new unwinder for larger full reel spools was installed on the winder.
Voith also was responsible for modernization of the paper machine controls and the OnQ ModuleJet profile control system. The complete contact-free drying as well as roll covers, clothing, and doctor blades were included in the project.
Together with the mill's PM 5, which also was provided by Voith Paper and likewise has a capacity of 300,000 metric tpy, Varel can now offer the entire range of products processed by the corrugating media industry on a 100% recovered paper basis.
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