1) PAPER MACHINE The paper machine is constituted by equipment manufactured by the following companies: Based on following project data: - CARCANO KMW - OMMA - DE PRETTO-ESCHER-WYSS - VOITH - VALMET COMO - SONOTEC - Effective width 3800 mm - Weight range 45-150 gsm - Machine speed 600 m/min - Production 130 t/d We have started with a Voith paper machine built in 1932 that we bought from Cartiere Sottrici Binda, Besozzo mill. As first and immediate step, the whole press section and the fourdrinier have been replaced. As second step, we have replaced the drying rolls, the headbox and the reel. Today, of the original machine, only the shoulders of the pre-drying section and some wire rolls remain. The drive arrangement of the machine has been partially recovered from Besozzo s machine, but later on it has been almost completely replaced. Steam system and hood were made new in 1992/93 and then again upgraded and modified in subsequent years. 4.1) HEAD BOX AND FOURDRINIER Headbox: by Valmet como, installed in 1995. Output width 4050 mm and 150 t/d production. Fourdriner: by OMMA, year 1992, in stainless steel and carbon steel lined with stainless steel sheet. Length 12850 mm, width 4200 mm. Upgraded by Valmet Como in 2001: the wire roll has been modified from stationary into swiveling and the pick up press has been modified into stationary. The suction roll, bought from Cartiera del Garda in 1992, is Carcano and has 762 mm diameter. 1
Picture n 28 Valmet headbox 4.2) PRESS SECTION Picture n 29 Fourdrinier Originally, the first press was a pick up assembly from Carcano with suction press roll dia. 812 and granite counter roll dia. 875 mm. In 2001 it has been upgraded by Valmet Como. 2
This press was bought originally from Cartiera del Garda in 1992. The second press was bought new in 1992 from De Pretto Escher-Wyss and it is constituted by a Nipco roll dia. 545 mm and by a 955 mm dia cylinder. From our data, we can say that dryness at the presses outlet was between 45 and 48 %. In the area under the first press and the wire roll there is the vat for the wet trimmings. The vat is in concrete lined with stainless steel sheet. The horizontal axes agitator is by Omma and it is complete of drive arrangement by motor and reducer. Picture n 30 Suction roll 1 st suction press 3
Picture n 31 2nd press with Nipco roll DP-EW Picture n 32 2 nd press hydraulic station (Nipco) DP-EW 4
4.3) PRE- AND POST-DRYING SECTION, SIZE-PRESS The drying section was rebuilt in 1995 by Valmet Como and is constituted by pre- and post-drying sections. The pre-drying section includes 17 drying rolls dia. 1500 mm, face 3950 mm, operating pressure 4,9 bar (Valmet Como). The pre-drying section is divided into 3 batteries, the first one is unirun type, the second and the third have top and bottom wires. The drying section shoulders have never been replaced but they have been reinforced. The post-drying section was also rebuilt in 1995 and it is formed by 10 drying rolls dia. 1500 mm, face 3950 mm, operating pressure 4,9 bar (Valmet Como). The first 2 dryers after the size press are Teflon coated and have no drying wire. The rest of the driers form a battery with two wires, top and bottom. The tail threading is performed by ropes. The groove for the ropes on the dryers is on the shell and not on the free pulley. In the end part of the post-drying section there is a Sonotec tail cutter (its operation to be verified). The drive arrangement of the drying batteries is by sectional motors and gears on the last driers of each battery. Because of the breakage of the toothed wheel of the 4 th battery (post-size dryers), CVR has eliminated the pertaining drive and has moved the two driers from the ropes of the rope run inserting them into the loop of the 5 th battery. Of course, the drive of the 4 th battery must be reassembled as per its original arrangement. The drying section is equipped with centralized lubrication system (Safematic) for the bearings supports, with single adjustment of the flows and alarm for lack of flow. picture n 33 Pre-drying section The size press was manufactured by Sonotec recovering the existing press rolls of the Voith machine of Besozzo mill, which rubber covering has been replaced. 5
Both the rolls are driven. Under the size-press there is no broke pulper, so the broke and the tail falling under the machine must be manually removed. In case of breakage of the sheet at the size press, it is necessary to thread the tail from the wire section. Picture n 34 Sonotec Size-press Picture n 35 Post-drying section 6
Pre and post-drying sections and size press are equipped with: # 1 open hood on the size press approx. dimensions 3 x 7 4,65 mt. # 1 closed hood thermo insulated on pre- and post-drying sections Approx.. dimensions: Pre-drying s. 18,5 x 7 x 4,6 Post-drying s. 8,5 x 7 x 4,65 Covering of the under the machine area appr. dim. 27 x 10 x 3,35 on three sides. Exhaust suction system, ventilation system in drying section, pre-heating coils, heat exchanger 1400 sqm. Room air ventilation Suspended ceilings system by aluminum corrugated metal sheet under hood lightning plant. The tube heat exchangers for hood ventilation require important cleaning operations. STEAM CONDENSATE, SATURATION AND MEASUREMENT SYSTEM Manufacturer: LANGBEIN ENGELBRACHT Including: Pumps Exchangers Electronic adjustments The control panel of the steam system is located in the control room. The instrumentation seems in god conditions. Supplier suggests to replace the membrane elements of the actuators and to check the regulations of the valves. 4.4) CALENDER, QUALITY CONTROL AND REEL Le calender was bought in 1992 from De Pretto Escher-Wyss; it is equipped with a Nipco roll dia. 500 mm and with an Equiterm roll dia. 660 mm. The hydraulic unit and the thermal unit of the calender are located in the basement under the machine. Also the driving motor of the top roll must be replaced. After the calender there are the fault detection system and the bridge measurement system (ABB) for the weight range and dryness with radio isotopes at low intensity (complying with safety rules, see report of Prof. Castello, qualified expert from the University of Genoa). The reel, manufactured by Valmet Como, was installed in 1995. Automatic type with spools parking. Equipped with 5 reel spools dia. 400 mm and dual joint. At the end part of the dying section, close to the reel, there is the broke pulper. The vat is Sonotec construction, the rotating unit is by De Pretto Escher-Wyss. Including drive arrangement by gearbox and motor. The two Nipco rolls and related machines (2 nd press and calender) are controlled by dedicated PLC. The reel is controlled by dedicated PLC. 7
Picture n 36 Calender with Nipco roll DP-EW 8
Picture n 37 Valmet reel Picture n 38 Control panel 9
5) REWINDER AND LOGS PACKAGING SYSTEM Le rewinder is located in front of the reel and the spools transfer from the machine to the unwinder is performed by bridge crane (15 tons capacity). 5.1) REWINDER Jagenberg rewinder type Vari Step TR 43 having effective trimmed width 3800 mm, max. speed 2000 mpm, 10 blades, max. dia. at inlet 2400 mm, max. dia. at outlet 1525 mm, complete of unwinder and devices for the complete control by PLC. Drive arrangement by Siemens, constituted by 3 motors in CC of which one is regenerative brake having 135 kw for the unwinder and two having each 120 kw for the drums. Draw adjustment by weighing cells. Trimming suction system with fan-tearing unit by IM-CO, compacting unit and separator located in the raw materials shed. By a pipe deviation, it is possible to send the trimmings to the broke pulper. The system has been bought new in 1992. Special fans for electrostatic discharge have been installed. Picture n 39 Jagenberg rewinder 10
5.2) LOGS PACKAGING The system was bought in 1993 from Sicma and includes a system by flappers to control the logs discharge and a rotating platform for winding with plastic film. A belt conveyor is installed at the inlet and at the outlet, for logs handling. A the end of the second conveyor there is an ejector pushing the packed logs in the picking up area, where they are picked by forklifts equipped with grippers. The plastic film winder is by Fis Impianti. Picture n 40 Packing system by Sicma/Fis Picture n 41 Packing system 11