The paper production line of the future

Our vision takes account of all important aspects for a well-balanced overall concept. The maintenance and operation of the facility are simplified, a higher degree of interconnectedness reduces interfaces, a more appealing design ensures a consistent overall look, while at the same time efficiency, safety and sustainability are improved.

To ensure that our customers can make even better use of the valuable feedstock of primary fibers, we are constantly refining and improving the components of our BlueLine stock preparation system. For example, an optical monitoring system on the rejects belt could identify fiber content and flakes and use these data to optimize downstream processes to minimize fiber loss. Thanks to these kinds of innovations, paper will contain an increasingly larger proportion of recycling fibers without compromising on quality.

Closed water loops are already a reality today, as treated and filtered water from the process is being re-used. This is the key to a significant reduction in water consumption during paper manufacturing. Our vision is to constantly reduce fresh water consumption to an even greater extent.

Another priority is to reduce energy consumption.  Our BlueLine stock preparation systems already use up to 20 percent less energy in the DIP process than standard systems. In the OCC process the energy reduction is as much as 25 percent.  And thanks to the use of a new kind of pyrolysis process, it may be possible in future, for example, to provide some of the thermal energy required by recovering thermal energy from biomass, without emitting CO₂ in the process. A first model system for this process is set to be launched soon.

In addition, Papermaking 4.0 not only offers a lot of tools for increasing efficiency and quality, but also helps to reduce the resources that your facility uses. Because sustainability in the paper manufacturing process can only be optimized efficiently if all cycles, consumption data and interdependencies are taken into account.

In future, Voith’s expertise as a full-line supplier is also set to be reflected in the design of a plant. From stock preparation unit through paper machine to winder, streamlined structures, high-quality surface finishes, modern materials and specifically selected machine illumination underline the special quality of a Voith production line. All along the XcelLine paper machine, a uniform cladding and continuous walkways are designed to create an uncluttered look.

Simple, reliable, intuitive: new concepts make the control and monitoring of paper production easier and more efficient than ever. On a standardized user interface you have an overview of all processes from stock preparation to reel. In this context, the human-machine interface uses a role-based operating concept to adapt to the individual task of the user, whereby each user can configure their own work area to ideally meet their requirements or use our established layout.

The preparation and representation of relevant data and KPIs will play an increasingly important role. This is made possible by self-configured dashboards and reports, whether in the control room, on office PCs or mobile devices. All information is available to the user wherever they need it at the time.

Easy-to-see SmartLights on individual system components also ensure more efficiency. They show you the status of the machine and if applicable, whether operator intervention is necessary. Optimized lighting of important work areas reduces the potential for errors, simplifies maintenance work and is also part of the user-friendly operating concept.

Sensors, field devices, scanners and actuators are already making a wealth of data available to your paper mill and form the basis for comprehensive real-time analyses. In future, however, the data will also enable very fast and reliable responses to changes in condition, which therefore minimizes downtimes because maintenance and servicing can be optimized pro-actively.

In future, digital instrumentation applications will be more widespread and so will be able to achieve more, as they interact with one another and respond to changes autonomously. Intelligent algorithms then ensure that the system optimizes processes autonomously. 

More complex does not mean more complicated. On the contrary! You can control and monitor all system functions via a platform, and optimize them with the help of data from the cloud. However, in our design concept this platform is also a networked interface to all service functions like ordering spare parts via the webshop, the remote service center OnPerformance.Lab, the video support for troubleshooting OnCall.Video, and many other applications that facilitate more efficient and sustainable production.

Resource savings, lower maintenance costs or greater autonomy are important building blocks on the road to more efficient paper manufacturing. And Papermaking 4.0 is the key. The Papermaking 4.0 apps provide optimum support to machine operators, paper technologists and maintenance personnel, so that they can focus completely on their core task, which is to produce paper efficiently in the right quality. Because these digital tools monitor the condition of the system at all times as well as the quality of the manufacturing process, identifying and reporting every deviation from the standard. In combination with highly efficient and reliable machines, unscheduled and costly downtimes are minimized.

Special attention has been paid to increasing cleanliness in the wet end by implementing ‘clean design’. Less fouling reduces the risk of unscheduled downtimes due to web breaks. Consequently, operational reliability and machine efficiency are improved. Even scheduled shutdowns are completed more efficiently thanks to more accessible work areas and simpler maintenance procedures. 

Well-illuminated work areas, wide walkways without landings, or stairways with lower step heights and glazed handrails don’t just improve the look of the machine. They are also elements of a comprehensive concept to make working on your production line safer.

Equally, Voith is working with its own security operations team of highly qualified experts to ensure, for example, that you can be confident that all your sensitive data on the dataPARC cloud.Platform will always remain exclusively in your possession. You decide how you access your data and control it for the respective application. In this context, Voith is combining maximum privacy, cyber security and top-rate infrastructure with its in-depth industry experience to help you navigate your digital future as our customer.

The theme of the sixth issue of our customer magazine is Discover! We put the spotlight on projects and products which as part of the Voith Paper strategy underpin our differentiation criteria “full-line supplier”, “sustainability” and “efficiency”.