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Kmw, Over Meccanica, Toscotec, Maule Bormida Paper Mill

Kmw, Over Meccanica, Toscotec, Maule Bormida Paper Mill

1. Main characteristics of PM 3
Construction year and installation  Completely rebuilt in 1993 - 1994
Manufacturers                                        KMW, Over Meccanica, Toscotec, Maule, GS Meccanica
Mill shut down 2011, December
Status of the machinery Completely assembled and serviced (no missing parts)
Type of machinery  Fourdrinier
Machine hand Right (drive on the right side when looking the reel from headbox)
Paper grade Linerboard (Test-liner) - double layer sheet structure
Raw material Mixed waste paper
Wire width 2.860 mm
Paper width at reel 2.560 mm
Paper width at winder 2.510 mm
Design mechanical speed 360 mpm
Max. operating speed (with size press) 300 mpm
Max. operating speed (without size press)       350 mpm
Max. production (with size press)  110 MTPD
Max. production (without size press) 150 MTPD
Brief description of PM 3 line Line Air cuschioned headbox, Fourdrinier wire section (bottom layer), mini Fourdrinier wire section (top layer) completed of secondary air cushioned headbox, press section (1st, 2nd and 3rd press), pre-dryer section (two tier type, double felted), inclined size press (pond type), post-dryer section (to tier type, double felted), reel (without automatic reel spool loading), two drum winder.
Dimension of the building
(PM 2 and PM 3 in the same location) 75 m (length) - 13 m (height) - 18 m (width)
Tension and frequency at mill  380 V - 50 Hz

2. PM 3 consumptions
Electrical energy 0.45 kWh/kg of paper
Saturated steam 0.5 kg/kg of paper
Fresh water 10 dm³/kg of paper

3. PM 3 description of the supply & services
The supply includes the following items:
common stock preparation system for PM 2 and PM 3;
PM 3 approach flow systems (bottom and top layers);
double layer paper machinery (PM 3) for linerboard (Test-liner) and related auxiliary systems;
two drum winder;
main spare parts for PM 2 and PM 3 (spares of the two machinery are interchangable);
Simeoni „Easy Float“ water clarifier;
non destructive dismantling service;
The items (1 - 6) are supplied “as is where is”. Mechanical reconditioning and the other services (see paragraph 9) are available under separate payment.
4. Exclusions
Steam generation plant and (2) double girder cranes serving PM 3 (6.0 and 6.3 Tons) are not included in the supply. In addition, the loading of containers onto trucks and the transportation service to the Buyer's site are not incluede in our supply.
5. Additional services available upon request
Services that PAPCEL, a.s. can offer to Buyers are the following:
transportation to Papcel and/or to Buyer's facility;
civil and process engineering;
paper machinery refurbishing;
provisioning of new PM parts and section's rebuild;
provision of new stock preparation equipment;
furnishing of PM auxiliary systems;
furnishing of starch preparation systems;
project management;
assembling on site;
start-up and personnel training;
furnishing of spare parts.

6. PM 3 technical specification
6.1. Approach flow system
Each line (bottom and top layers) is composed by:
(2) stages low consistency cleaners („Palmac“);
low consistency pressure screen for headbox protection („RCM“ for bottom layer and „Black Clawson“ for top layer).
Type of approach flow systems: single dilution.
6.2. Primary headbox (bottom layer)
Primary headbox having the following main characteristics:
designed, manufactured and installed by KMW in 2002;
closed, pressurized with air cushion;
equipped with circular tapered manifold (with recirculation pipe and balancing flow control system), tube bank, perforated plate, internal rectifier rolls and manual slice lip control;
design speed of 600 mpm;
design production of 9 T/h;
in full stainless steel material;
complete of devices for vertical and horizontal top slice regulation (flow regulation and impingement point control);
fixed to baseplates anchored to concrete basements;
complete of longitudinal (for Fourdrinier inspection) and transversal walkways (headbox control).
6.3. Fourdrinier (bottom layer)
Wire section having the following main characteristics:
in cantilever (avarage time for changing the wire to be around 3 hours);
in carbon steel lined with stainless steel sheets;
wire width of 2.860 mm;
wire length of 3.2500 mm;
fixed brest roll 580 mm diameter (no shaking device), rubber covered;
(1) forming board comprising (6) blades in ceramic material;
(1) foil box „IBS“ comprising (8) blades in ceramic material;
(1) foil box „Maule“ comprising (5) blades in ceramic material;
(2) foil boxes „Huyck“ comrising (7) blades in ceramic material;
(2) hydrofoils „Huyck“ with (5) blades in ceramic material;
(1) low vacuum box „Huyck“ with (11) blades in ceramic material;
(1) low vacuum box „FTK“ with (11) blades in ceramic material;
(1) duoflo low vacuum box „FTK“ with (11) blades in ceramic material;
(8) high vacuum boxes „Huyck“ with PE covering material („Robaglas“);
(1) high vacuum box „Huyck“ with ceramic covering maaterial;
(1) sheet transfer box „IBS“;
(1) couch roll 500 mm diameter, driven (260 kW), rubber covered;
(1) turning roll (helper) 400 mm diameter, driven (92 kW), rubber covered;
wire guide rolls 240 and 280 mm diameters, rubber covered;
complete of pneumatic wire stretcher and guide roll device;
complete of wire and rolls cleaning system;
complete of alluminium stairways and walkways;
multi-layer wire in synthetic material based on polyester and polyamide;
25% max. dryness (reached in the best paper machine condition).
6.4. Secondary headbox and Fourdrinier (top layer)
„Over Meccanica“ secondary headbox, air cushioned type, design speed of 1.350 mpm, capacity of 4.5 T/h, in cantilever.

Wire section having the following main characteristics:
designed, manufactured and installed by „Ing.S.Maule&C.S.p.A“ (Maule);
in cantilever;
in carbon steel lined with stainless steel sheets;
wire width of 2.860 mm;
brest roll 460 mm diameter, rubber covered;
(1) forming board comprising (6) blades in ceramic material;
(1) foil box with PE blades („Robaglas“);
(1) foil box with (5) PE blades („Robaglas“);
(1) duoflo low vacuum box „FTK“;
(2) high vacuum boxes „Huyck“ with PE covering material („Robaglas“);
(1) wire roll 460 diameter, rubber covered;
(3) wire guide rolls 330 mm diameter, rubber covered;
(1) driven roll 660 mm diameter, rubber covered (92 kW);
complete of pneumatic wire strecher and guide roll device;
complete of wire and rolls cleaning system;
complete of alluminium stairways and walkways;
multi-layer wire in synthetic material based on polyester and polyamide.
6.5. Press section
Press section having the following main characteristics:
designed and manufactured by „Maule“ and „Over Meccanica S.p.A“.
felted lump-breaker roll 690 mm diameter (against the couch roll), plain rubber covered and pneumatically loaded („Over Meccanica S.p.A“);
double felted 2nd press with 590 mm diameter rolls, plain rubber covered and loaded by pneumatic system („Maule“);
bottom single felted Jumbo press with 880 mm diameter rolls, plain rubber covered and loaded by pneumatic system („Maule“);
cantilevered press framework in painted carbon steel;
complete of felt conditioning system;
complete of pneumatic felt stretcher and felt guide device;
felt based on high-tech textiles (polyamide 6 and polyamide 66);
45% max. dryness (reached in the best machine conditions).
The felted lump-breaker press (lump-breaker against the wire couch roll) is not a very common configuration, but it is effective in gaining a few percentage dryness points.

Press section sketch
Note: this sketch comes from the mill and it is not very precise (updated). The top felt cannot come out that way from the second press (felt guide roll missing).
6.6. Pre-dryer section
(3) conventional double felted pre-dryer batteries composed by:
(11) cast iron dryer cylinders 1.250 mm diameter, 2.750 mm of roll face, 2.5 bar steam pressure;
(8) steel dryers „TT Steel Dryer“ (Toscotec S.p.A) 1.500 mm diameter, 2.900 mm of roll face, 10 bar steam pressure, with plain heads directly welded on the dryer's shell;
felt rolls 280 and 340 mm diameter, rubber covered;
cast iron framework (painted);
drive by open gearboxes (drive side);
dryers equipped with static syphons;
dryers certified in accordance with Italian regulation (ISPESL certification);
complete of felt stretcher and felt guide device;
complete of felt conditioning system;
complete of fixed doctors manually loaded (blades in composite material, glass fiber);
complete of rope threading system;
centralized lubrication system for dryer's bearings;
dryer fabric made from polyester based polymer derivates.
6.7. Size press
Superficial application of starch by Size press having these main features:
inclined, puddle type (flooded nip);
designed, manufactured and installed by „Toscotec S.p.A“;
(2) sizing applicator rolls 600 mm diameter, rubber covered;
framework in carbon steel;
complete of rope threading system;
complete of stairway and walkway in aluminium material;
complete of starch preparation systém (see paragraph 6.3.10);
Note: starch is also applied by mass in order to improve the paper runnability (> efficiency).
6.8. Post-dryer section
(1) conventional double felted pre-dryer section composed by:
(2) cast iron dryer cylinders 1.500 mm diameter, 2.900 mm of roll face, 3.5 bar steam pressure;
(6) steel dryers „TT Steel Dryer“ (Toscotec S.p.A) 1.500 mm diameter, 2.900 mm of roll face, 10 bar steam pressure, with plain heads directly welded on the dryer's shell;
first post-dryer cylinder with superficial chrome application;
felt rolls 340 mm diameter, rubber covered;
cast iron framework (painted);
drive by open gearboxes (drive side);
dryers equipped with rotary syphons;
dryers certified in accordance with Italian regulation (ISPESL);
complete of felt stretcher and felt guide device;
complete of felt conditioning system;
complete of fixed doctors manually loaded (blades in composite material, glass fiber);
complete of rope threading system;
centralized lubrication system for dryer's bearings;
dryer fabric made from polyester based polymer derivates.
6.9. Reel
Conventional reel drum having the next coming features:
designed, manufactured and installed by „Over Meccanica S.p.A“;
framework in painted carbon steel;
mounted on painted carbon steel frameworks (height of reel section in accordance with safety regulations);
primary and secondary arms pneumatically loaded;
drum of 1.000 mm diameter;
(8) reel spools of 250 mm diameter;
max. wounded roll diameter of 1400 mm;
rails designed to accommodate (1) finished roll with running reel;
complete of stairway and walkway in painted carbon steel material;
complete of safety protections (to be modified, not in accordance with safety regulations);
without reel spool loading (the crane is used for changing the reel spool);
manual tape turn-up for reel spools change.
6.10. Miscellaneous
Closed pre-dryer and post-dryer section hood designed and manufactured by the Italian „Novimpianti Drying Technology S.r.l“.
„Novimpianti Drying technology S.r.l“ steam and condensate system (cascade configuration).
„Fomat Automation“ QCS system installed in 2007.
Vacuum system composed by „Azmec“ vacuum pumps types AL65 (160 kW), ALZ80 (90 kW), ALZ100 (110 kW) and (2) Metso centifugal fans of 1.800 Nm³/h and 450 Nm³/h (fans not included in the supply).
Compressed air system comprising (2) compressors „Pneumofore“ UP 12 type (7.5 bar) and UP 18 type (8.5 bar) servicing all consumptions (UP 18 compressor not included in the supply).
Enzymatic conversion cooker „Amylum“ for native starch application.
PM 3 DC sectional drive.
PM 3 is equipped with a concrete couch pit under the main wire section and (1) UTM pulper under the reel section made in stainless steel material.
6.11. Winder
Winder having the following main characteristics:
designed, manufactured and installed by „Over Meccnica S.p.A“;
two drum type;
(2) drums diameter of 400 mm
installed power of 110 kW;
framework in painted carbon steel;
maximum speed of 800 mpm (2.3 times the machinery speed);
maximum operating paper width of 2.560 mm;
maximum parent roll diameter of 1.400 mm;
maximum finished roll diameter of 1.400 mm;
mechanical brake on the unwind station;
(2) knives for trimming edges, manual positioning;
TNT control (tension, nip load and torque);
complete of trims removal system.
7. Stock preparation system
There is a common stock preparation feeding both PM 2 and PM 3 for a total production of around 230 BDTPD.
The system does not include the PM 2 and PM 3 approach flow equipment which are part of the respective machinery. Our supply includes all the stock preparation goods (for PM 2 and PM 3). The following block diagram shows how the common stock system is composed.
8. PM 3 mechanical conditions
PM 3 (lot 2) has been almost completely rebuilt in the years 1993 - 1994. A paper machine aged 20 years is to be considered still capable of producing paper for a long time (at least for other 20 years). Nowadays, paper machines originally dating from 1965 are successfully being sold by European mills and relocated in foreign countries, especially in fast growing economies. All PM parts in stainless steel such as headbox, wire section, mini wire-section and secondary headbox are in good condition (no trace of superficial corrosion by aggressive chemical agents).
The press section framework should be cleaned, subject to sand blasting and repainting even if there are no visible signs of corrosion.
Stairways and walkways in aluminium material are in very good condition.
The pre-dryer and post-dryer sections in cast iron material are in good condition.
The reel section staircase and walkway is to be cleaned and painted; its safety protections are to be designed and manufactured as new, the present ones do not meet any safety regulation. New safety protections are recommended for the winder.
The PM 3 is complete with all components, there are no missing parts that have been stolen (with the exception of wire cables), completely or partially dismantled or damaged. The facility is guarded night and day as prescribed by Italian law.
9. PM 3 technology overview
Declaring beforehand that any paper machinery should be evaluated in respect of the buyer's requirements and perspectives, PM 3 of Italian Bormida mill is still to be regarded as machinery of very good technology, especially for what concerns the structure of the forming sheet. In detail, the press section - regardless of what the paper dryness rate might be before entering the pre-dryer section - is characterized by narrow and extended nips which positively affect bulk and, consequently, the paper resistance to be folded. The third press is a „mini Jumbo“ as the diameter of rolls is 880 mm only. In order to obtain a very extended nip pressure, Jumbo rolls having 1.500 or 1.800 mm diameter should be used or, as a better alternative, an ENP press (shoe press).
The wire section, composed of a main Fourdrinier (bottom layer) and a mini Fourdrinier (top layer) are still of the latest technology for linerboard grades.
Pre-dryer and post-dryer sections are of conventional type, two tier double felted. In this specific case, the open gearboxes on the drive side improve the humidity profile of the sheet throughout its width. Doctoring is performed with manual doctors equipped with blades of the latest design. Both the pre-dryer and post-dryer sections are equipped with a certain number of steel dryers with plain heads directly welded on shells „Toscotec“ design. This solution has two remarkable advantages: a) better humidity profile at paper edges; b) higher drying capacity.

„Toscotec“ inclined size press - puddle type - is still used today with great success even though a film press would generally reduce the post-dryer section length as it works with a significantly higher concentration of solids (less water to evaporate). Nevertheless, considering the speed of Bormida PM 3 machine, the puddle type size press is still good machinery where the surface application (gsm on both sides of the sheet) of starch (or any other sizing substance) is controlled by mechanical nip pressure of applicator rolls, by pond height (hydrostatic pressure), by starch concentration and base paper properties. The inconvienience of the inclined type is the non uniformity of starch application of both sides, but where this represents a not negligible problem the size press can be equipped with (1) applicator roll of bigger diameter. The last consideration is that size presses contributes to production losses for about 20 - 25%, therefore its usage is to be properly evaluated.

PM 3 reel section is a classic drum type which can be implemented with the automatic reel spool loading.
The two drum winder - „Over Meccanica“ design - is fine with 1.400 mm diameter parent roll. The unwind station is operated manually (tension provoked by the two drum rotation and brake on the unwind section) and for packaging grades the slipping roll inertia compensation obtained by a regenerative electric motor is not required.

Ref. No.  71329