LEIPA and Voith Set New Benchmark with PM 5 in Schwedt

In Schwedt, Germany, Voith has converted the LEIPA Group’s PM 5 from a newsprint to a packaging paper machine. On April 19, 2018, acceptance and handover of the machine (PM 5) was signed early at LEIPA Georg Leinfelder GmbH, effective April 13, 2018.

As a result, the Voith team on site managed to bring the entire machine, consisting of a BlueLine OCC stock preparation line, DIP stock preparation line, and XcelLine paper machine up to handover quality just 19 days after ‘stock on wire.’

Perfectly matched components and an extensive automation system, including OnQ quality control system, make the machine a new benchmark in the industry. LEIPA can produce approximately 450,000 metric tpy of white top testliner (WTTL) on the machine and is therefore the market leader in this segment.

After taking over the UPM mill in Schwedt, the new owner, the LEIPA Group, decided to extensively rebuild the existing PM 11. Under the management of Voith, the conversion of the newsprint paper machine to a machine for the production of WTTL began in October 2017. LEIPA invested more than EUR 160 million in the plant.

Now known as PM 5, the machine is a new point of reference for packaging paper. Just a few machines worldwide surpass its 9,200-mm wire width. It also takes the top spot with its production speed of 1,200 m/min. LEIPA plans to produce 1,180 to 1,400 metric tons of WTTL per day with the best surface properties and basis weights of 100 to 140 gsm. LEIPA wants to manufacture a total of 450,000 metric tons of paper every year and thus further expand its market position.

LEIPA PM 5 project team, from left to right in photo above: Martin Kaltenegger, project manager LEIPA PM 5, Christian Merz, chief commissioning engineer at Voith Paper, Falk Friedrich, plant manager at LEIPA Schwedt Nord.

To ensure PM 5 can meet the desired output and quality requirements, Voith modified almost every component of the existing machine. A new hybrid former with two headboxes—DuoFormer D and TopFormer F—replaced the previous former, for example. Voith also developed a comprehensive solution for the transition to the press section and for the press, with a DuoCentri NipcoFlex shoe press in the center. These two components were designed to meet the requirements in high speed machines and enable outstanding product quality. Robust SolarPress roll covers assist in achieving this. The covers do not require any water cooling and help LEIPA to conserve resources. The SpeedSizer AT is also optimized for the uniform and faultless application of starch at high speeds.

During the rebuild, Voith separated the existing dryer section into a pre-dryer and after-dryer section. In the process, the pre-dryer section received a completely new TopDuoRun dryer group, while existing components were used for the after-dryer section.

Thanks to a new MasterReel reel and the rebuild of the two existing DuoRollers, reel diameters of up to 3.5 meters can now be produced on PM 5. The existing machine hall ventilation system was also expanded and integrated into the new process and quality control system.

Some of the existing motors were also used after the conversion. However, the Voith team integrated more than 333 new motors of different sizes into PM 5, the most powerful of which has a capacity of 1.5 MW. Most of the motors are integrated into the automation concept developed by Voith.

The system records more than 15,000 signals, monitors all of the production steps from stock preparation to the reel, reports even the slightest deviations, and levels out any fluctuations within a fraction of a second where needed. A total of 29 state-of-the-art computer processors take care of processing the information.

"The continuous data stream forms an important basis for us to maintain a consistently high paper quality at all times,"said Falk Friedrich, plant manager of LEIPA Schwedt Nord.

While the rebuild was taking place, a new machine for the efficient treatment of up to 1,400 metrics tons of fiber from recovered paper per day was also built. With a length of 50 meters, a diameter of 4.5 meters, and a total weight of about 200 metric tons, the IntensaDrum pulping drum is the largest Voith has supplied to date. Much of the existing deinking system (DIP) was retained. Voith only had to modify it to cope with the characteristics of packaging papers.

Among other measures, the technology group installed energy-saving components for bleach and flotation, which, along with the new cleaning system, reduce fiber losses.

"The engineers from Voith view the system from the apron conveyor to the winder, including measuring, automation, and ventilation technology as a whole, and therefore develop perfectly compatible solutions," emphasized Martin Kaltenegger, Project Manager for LEIPA PM 5.

In addition, the order volume included startup and a number of training sessions in which the LEIPA team became familiar with the intricacies of PM 5. Voith also will remain closely involved in the processes of PM 5 after startup. In the next few years, the single-source supplier will deliver the clothing and doctor blades for the machine and thus ensure the optimum performance of PM 5. The optimization of the machine within the first eight weeks after startup is also part of the project – with an option to extend it for longer.

"The entire project, from the shutdown of the PM 11 to the installation of the new components and start-up of new PM 5 has gone very well. With their professionalism and dedication, the two project teams have ensured the success of the project," said Robert Osswald, project manager, Voith Paper