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Less is more: FlowJec saves resources

Improved efficiency through innovative dosing technology

2014-06-11 - The new FlowJec dosing system from Voith has been in use at Smurfit Kappa Zülpich Papier for nearly three years. Measurements during this period confirm the capability of the system. It was demonstrated that the number of breaks decreased on average by 3.5 per week and also that 11,000 m3 less fresh water per year is now consumed than previously. The use of retention agent has noticeably decreased – due to that alone the investment at Smurfit Kappa was amortized within one year.

With FlowJec, Voith is the first provider to bring to the market an innovative dosing system for process chemicals and additives. Its variable dosing makes precise and homogeneous mixing of chemicals and additives possible. While conventional technologies can dispense too high a concentration at the dosing point, the FlowJec dosing system brings exactly the right amount of chemicals to the right place in the process stream. What sounds simple is actually the result of intensive development work.
“With FlowJec, we are achieving an improved paper quality, savings of up to 10% of the retention agent, fewer breaks, an increasing running time and consequently a higher efficiency of the paper machine.”
Jochem Meier, Head of Production at Smurfit Kappa Zülpich Papier
Exact dosing and homogeneous mixing. FlowJec can be used in the low consistency as well as in the high consistency stock area of the approach flow system and – a decisive advantage – installed at the optimal points in a targeted fashion. It is possible to dose several chemicals and additives at the same time at a single point in the stock line. Depending on the requirements, FlowJec is delivered with one or up to six dosing nozzles, the AddJectors. All necessary chemicals and additives can be fed into the process stream via the dosing nozzles.
Homogeneous mixing is achieved by not pouring the additives directly into the process stream but instead first mixing them with the process medium. This takes place in the AddJectors, the core of FlowJec. No fresh water is used; instead, process media such as the stock suspension itself, white water, filtrate or flotation is used. There is therefore no need for a step like post-dilution with fresh water in e.g. the dosing of retention agent.
The advantages are obvious: consumption of chemicals, additives and fresh water is reduced. As a result, the energy consumption of the paper machine is also reduced, since less fresh water has to be heated. Other effects of homogeneous mixing are the measurable improvement of paper quality, optimal flocculation and better runnability of the paper machine.
FlowJec at work at Smurfit Kappa. In Zülpich the company produces liner and corrugating medium on its two-layer PM 6 packaging paper machine. The first FlowJec dosing system was installed here nearly three years ago. Jochem Meier, Production Manager at Smurfit Kappa, sums up: “The FlowJec dosing system on the PM 6 was designed so that both the stock suspension as well as the white water can be used as an injection medium. With both media, we achieve a retention agent saving of 10% over the entire grade range. Another big advantage is that with the FlowJec system the dosing concentration of the retention polymer can be increased from 0.35% to 0.8%. Just because of that we can save 1,500 liters of fresh water per hour.”
Substantial advantage for maintenance. FlowJec is the only dosing system in which the dosing nozzles have an automatic cleaning system. The maintenance outlay is thus substantially reduced and as a consequence the process availability is increased. FlowJec is completely integrated in the process control system of the paper machine.
Meanwhile, FlowJec is also used at other paper manufacturers, and Voith Paper is currently working on development of a smaller FlowJec variant for paper machines with an annual production of

50,000 – 250,000 metric tons. This variant will soon be launched on the market.


Advantages at a glance

  • Better runnability: 20% - 30% fewer breaks
  • Reduced fresh water consumption (11,000 m3/a)
  • Better formation (9%)
  • More uniform distribution of ash (6%)
  • Reduced chemical consumption
  • Reduced energy consumption
  • Integrated cleaning function
  • Simple installation and easy maintenance
  • Amortization in less than 12 months