In April 2015, Smurfit Kappa Saillat (France) awarded PMP (Paper Machinery Producer), Poland, a wet end rebuild of its PM 4. On Jan. 8, 2016, at 7:00 p.m. local time, PM 4 was successfully brought on-stream at the Saillat mill. At the same time, saleable paper parameters were achieved just 1.5 hour later. 

 

The main goals of the project were to improve paper quality (basis Weight CD profile, TSO profile, and 2 sigma COV), as well as to increase PM 4 capacity. 

 

PMP’s scope of delivery included a 4-channel Intelli-Jet V® (hydraulic headbox) for a top ply, a pressure pulsation attenuator system, a temperature control system, and a wire rebuild (top ply mini-fourdinier). The new hydraulic headbox assures significant improvement of basis weight profile, uniform paper web structure, and significantly better formation. 

The temperature control system minimizes CD slice open deviations due to thermal, pressure, and gravity forces, but also minimizes production loses. PMP also was responsible for a vacuum system, on-site erection, and startup supervision. 

The delivery was divided into two stages: 

• 1st stage—during August 2015. Erection of a top mini-fourdrinier, including a vacuum system installation and a save-all system.
• 2nd stage—during January 2016. Erection of a top ply Intelli-Jet V hydraulic headbox with consistency profiling and a new turning roll, followed by commissioning and startup supervision.

Main project achievements are: 

• The TSO profile of top ply range increased significantly.
• The dry basis weight profile 2 sigma in the cross machine direction (CD) was improved. 
• Top layer formation also was improved. Formation improvement can be seen in a much better top side smoothness. 
• Final product formation has been improved as well. 
• As a result of better tuning allowed, operating machine speed also increased. 

PMP Intelli-Jet V hydraulic headbox technology is a leading solution in the pulp and paper industry. It is a part of the PMP Intelli-Paper® platform for papermakers. There are more than 130 units working successfully on six continents. 

Smurfit Kappa is a global provider of paper-based packaging solutions, with more than 43,000 employees across 33 countries. The company is located in 21 countries in Europe, 12 in the Americas, and is the only large-scale pan-regional player in Latin America. Smurfit Kappa’s Saillat mill is located in Saint-Junien, in central France, with nearly 130 employees.