Keeping Track

New Automation Tools for Stock Preparation Expand Voith’s MillOne Ecosystem for More Process Autonomy in OCC Lines

paperasia
  • Solutions for optimising pulping, fine screening and high-density cleaning with seamless integration into the MillOne ecosystem
  • Autonomous optimisations through data analysis and decision making enable a more efficient and stable OCC line process
  • Optimisation of data and resource usage supports ease of operation and the way towards autonomy 
  • Schoellershammer convinced of the benefits

With the introduction of three automation solutions – OnControl.SmartProtect, OnControl.FineScreening and OnControl.Pulping Detrashing – Voith is expanding its MillOne ecosystem and driving forward the digital transformation of papermaking. Designed to solve daily challenges of operators in pulping, fine screening and high-density cleaning, the solutions consolidate excessive amounts of data, complex decision-making processes and inefficient manual interventions through real-time measurements, data analysis and automated adjustments or recommendations. Companies such as German papermaker Schoellershammer are benefitting by significantly optimising their production output and resource utilisation. 

Self-optimising heavyweight reject traps with OnControl.SmartProtect
OnControl.SmartProtect improves high-density cleaning performance by continuously monitoring the reject level in the high-density chamber, automatically adjusting the flushing water quantity accordingly and adapting the emptying process in real time to the current reject quantities. This ensures that rejects are rinsed as thoroughly as possible, and cycle times are optimised to save fibre and energy costs and increase wear parts lifetime. 

Schoellershammer is already using the solution at its German site in Düren and is seeing savings in operating costs.

Since installing OnControl.SmartProtect, we have recorded lower fibre losses and less wear on the gate valves, as they have to be operated less frequently. The high separation efficiency also protects the downstream machines.

Armin Vetter, Managing Director of Schoellershammer

OnControl.FineScreening warns of dirt peaks in real time
OnControl.FineScreening controls the reject flow based on real-time information about stock quality. Depending on the quality of the fine screening accept, the process parameters are automatically adjusted to keep fibre loss as low as possible, resulting in optimised resource utilisation and cost savings. 

Depending on the fibre quality, our customers were able to save up to four tons of raw material per day during the pilot installation.

Flavio Granito, Global Product Manager Papermaking 4.0 at Voith Paper

“With the new digitisation solution, we were able to significantly reduce waste in slot sorting,” reported Vetter. “The installation has already proven to be very profitable.”

OnControl.Pulping Detrashing for improved control and performance optimisation in the pulper detrashing system
The tool is applied in the pulping and detrashing module of the stock preparation, where the frequently fluctuating raw material quality presents paper manufacturers with challenges. To optimise plant operation, OnControl.Pulping Detrashing monitors parameters that are influenced by the composition of the recovered paper fed to the pulper and automatically adjusts the process parameters in real time based on this analysis. 

“The control system calculates detrashing cycles individually and reacts very well to fluctuating reject quantities,” reported Karl Tessler, Senior Plant Manager at Schoellershammer. “As a result, OnControl.Pulping Detrashing has noticeably increased our operational reliability. Disturbances caused by blockages and downtimes due to overcurrent on the motors no longer occur when the control system is switched on. The rejects disposed are less contaminated with fibres, which in turn increases the fibre yield. Overall, OnControl.Pulping Detrashing proves to be a modern control system that makes full use of technical possibilities,” Tessler concluded.

Three tools, one system
The three tools can be integrated seamlessly into Voith’s MillOne ecosystem, which brings together all mill data in one system. Its direct communication with individual modules enables machines and processes to be monitored more efficiently, as individual data sets are consolidated and analysed holistically in real time. This supports early detection of potential issues and allows for immediate automatic or manual intervention when necessary. As a result, complexity is reduced, and operators save time. The new solutions are another big step toward autonomous stock preparation and, ultimately, toward the autonomous paper mill.

Find more information on the website: https://voith.com/corp-en/industry-solutions/papermaking/autonomous-paper-mill/millone.html

About Schoellershammer
Schoellershammer GmbH, based in Düren, has a long-standing tradition in the paper industry, with roots dating back to the 18th century. The company remains family-owned to this day. As early as 1950, Schoellershammer recognised the potential of the circular economy and commissioned its first paper machine for recycled paper. It aims to be one of the most sustainable manufacturers and partners in the European packaging market. As a non-integrated manufacturer, Schoellershammer does not compete with its customers and suppliers.

Schoellershammer produces over 540,000 tons of liner and fluting paper annually, using wastepaper sourced from the region. The company operates two paper machines, PM5 and PM6, the latter of which was commissioned in 2016 and is one of the most energy-efficient paper machines in Europe. Schoellershammer manufactures containerboard exclusively from secondary fibres. In addition to standard grades, which account for about three-quarters of production, the company also produces high-performance grades, including the proprietary containerboard brands Hammerliner and Hammerflute. Its high-performance Twinhammer brand is suitable for both testliner and fluting, simplifying raw material procurement and storage for its customers and enabling more sustainable, lighter packaging. All Schoellershammer products are FSC® certified (FSC® C109985).

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, paper, raw materials and transport. Founded in 1867, Voith today has around 22,000 employees, sales of EUR5.2 billion and locations in over 60 countries worldwide and thus is one of the larger family-owned companies in Europe.

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 and products on the market and offers paper manufacturers holistic solutions from one source. The company’s continuous stream of innovations facilitates resource-conserving production and helps customers minimise their carbon footprint. With its leading automation products and digitalisation solutions from the Papermaking 4.0 portfolio, Voith offers its customers state-of-the-art digital technologies to improve plant availability and efficiency for all sections of the production process.