dryer section performance

Transcription

www.paperage.com
JANUARY/FEBRUARY 2014
DRYER SECTION
PERFORMANCE
Five easily applied
dryer performance
indicators make
way for optimal
energy efficiency
CONTAINERBOARD
Capacity bulge,
sluggish demand
remain challenges for
containerboard market
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contents
JANUARY/FEBRUARY 2014, Volume 130, Number 1
C O L U M N S
14Market Grade: Containerboard
2013 wasn’t a bad year for containerboard mills
but results were decidedly mixed. Price increases
were enacted on board and corrugated boxes in
early 2013 that boosted margins, but underlying
box demand was stagnant. 2014 offers hope
that improved economic growth can propel box
demand to stronger gains, but the impact of
new containerboard capacity remains a nagging
concern.
18
F E A T U R E S
18Easy-to-Apply Dryer Performance
Indicators
The dryer section is a large consumer of energy,
but ensuring it is operating efficiently is not
difficult. By assessing only a few easily applied
“dryer performance indicators”, one can determine whether large improvement opportunity
exists.
16Heads-Up: Quiet Start in Europe
The European paper industry is off to a relatively
quiet start in 2014, and industry observers say
the year may continue as such, which may be a
good thing.
30 Recycling Matters
Continuous commitment to paper recovery for
recycling paper recovery has fostered a dynamic
marketplace that allows recovered fiber to find
its highest-value use, which helps to encourage
even more recycling.
D E P A R T M E N T S
22Microbiological Auditing and
Control – A New and Powerful
Approach to Controlling Problem
Organisms
4 Editor’s Note
A genetic-based technique used to detect and
identify troublesome microbes in paper mills’
fresh water systems has been found to be quick,
accurate, and less cumbersome than traditional
methods.
13 Calendar
26 Keep it Running Smooth
To succeed in today’s fiercely competitive marketplace, pulp and paper manufacturers positively,
absolutely, require maximum equipment availability
and productivity from their machinery, and a
disciplined lubrication management program can
make this happen.
6 Industry News
12 People
S E R V I C E S
29 Classified Ads
29 Index of Advertisers
PaperAge J A N U A R Y / F E B R U A R Y 2 0 1 4
3
editors note
If at first you don’t
succeed…
EDITOR IN CHIEF
Jack O’Brien
By John O’Brien, Managing Editor
PUBLISHER
Michael C. O’Brien
MANAGING EDITOR
John F. O’Brien, Jr.
CONTRIBUTING EDITOR
Harold M. Cody
CONTRIBUTING WRITER
David Price
CONTRIBUTING WRITER
John Yolton
LAYOUT & DESIGN
George H. Dean Co.
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JANUARY/FEBRUARY 2014
VOLUME 130, NO. 1
. . . try, try again. With that in mind, Verso
improved if Verso was able to acquire
Paper on January 6 announced that it would
NewPage’s assets at fire sale prices or if debtors
acquire NewPage in a deal valued at $1.4
fail to reorganize; (2) Verso is significantly
billion. This will be a very big deal if the two
threatened by the possibility that NewPage
companies can actually get past the initial
will successfully reorganize under a stand-
proposal stage. They’ve been down this road
alone plan and emerge from bankruptcy a
before and it has been a very, very bumpy
stronger, healthier company with a deleveraged
ride to say the least.
balance sheet; and (3) Verso stands to benefit
Phone: (781) 923-1016
As some may recall, the on-again, off-again
from any delays in the debtors emergence
Fax: (781) 923-1389
romance between Verso and NewPage dates
from bankruptcy and can be expected to
back to 2010 and early-2011. At that time,
oppose all stand-alone plan proposals and any
private equity owners, Apollo Management
near-term restructuring.
(Verso) and Cerberus (NewPage), were repor-
Over the summer of 2012, the two com-
Scituate, MA 02066-3743
tedly in talks that most industry observers pre-
panies sparred until Verso on Sept. 4 finally
Phone: (781) 378-2126
sumed were about the combination of North
called a halt to its pursuit of NewPage, stating
America’s two largest coated paper producers.
that “it has decided to cease further discussions
However, many analysts pointed out that the
with NewPage Corporation or its creditors
two papermakers carried much too much debt
regarding a potential business combination.”
for the deal to make financial sense, especially
Or maybe not. After a 16-month regroup-
to certain groups of lienholders.
ing period, both parties, it seems, have had a
Nothing, it appeared, but speculation
change of heart and are in agreement to the
resulted from those talks, and on September
structure of a new deal (see page 6) — a very
7, 2011, NewPage filed for creditor protection
complicated deal. In a recent presentation by
under Chapter 11.
Verso, “NewPage Operating Company would
As NewPage moved into its tenth month
be a non-guarantor restricted subsidiary for
of reorganization, Verso on July 2, 2012
Verso’s notes with a standalone capital
announced that it had “held discussions with
structure.”
certain holders of the 11.375% first-lien senior
Moody’s Investor Services explains it
secured notes of NewPage Corporation in an
like this, “It is anticipated that following the
effort to achieve a potential business combina-
acquisition, Verso and NewPage will be run as
tion involving Verso and NewPage as part of a
separate legal entities with a shared services
converting industries. To all others there is a subscription
consensual plan of reorganization in NewPage’s
agreement.”
charge of $54.00 in the U.S., $60.00 in Canada, and
Chapter 11 bankruptcy proceedings.”
Regardless of the complexities, Verso has
How did that proposal go over? Not very
hung in there, I’ll grant it that. And although
well; not very well at all. Just ten days after the
there remains a lot of people to satisfy, includ-
proposal, an attorney representing holders
ing possibly antitrust regulators (Verso and
of first-lien debt strongly rebuffed the deal in
NewPage would have at least 50% of the
a letter to Judge Kevin Gross, U.S. Bankruptcy
coated freesheet market), perseverance may
Court in Delaware. The letter concluded that
be the lynchpin that sees the deal through
(1) Verso’s market position would be greatly
this time around. n
4
J A N U A R Y / F E B R U A R Y 2 0 1 4 PaperAge
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industry news
NORTH AMERICA
Verso Paper to Acquire NewPage in $1.4 Billion Deal
Verso Paper and NewPage on
Jan. 6 announced a definitive
agreement under which Verso
will acquire NewPage in a transaction valued at $1.4 billion.
Upon closing of the deal, the combined company will have
sales of approximately $4.5 billion and 11 manufacturing facilities located in six states.
The transaction, which has been unanimously approved by
the boards of directors of both companies, is expected to close in
the second half of 2014, subject to regulatory approvals.
“The combination of Verso and NewPage will create a stronger business that is better positioned to serve our customers
and compete in a competitive global marketplace,” said David J.
Paterson, Verso’s President and CEO.
“We continue to face increased competition from electronic
substitution for print and international producers, but as a larger,
more efficient organization with a sustainable capital structure, we
will be better positioned to compete effectively and deliver solid
results despite the industry’s continuing challenges. Furthermore,
we believe the transaction provides stakeholders in both
companies with meaningful, compelling value,” Paterson said.
The combination of the two companies is expected to result
in at least $175 million of pre-tax total cost synergies, which are
SP Fiber Technologies to Convert
Newsprint Machine in Newberg Mill to
Lightweight Containerboard
SP Fiber Technologies, LLC (SPFT) announced plans to
convert a newsprint machine at the company’s Newberg,
Oregon paper mill to produce lightweight containerboard.
PM5 ceased production of newsprint on January 15 to
allow for necessary process modifications, the company said.
The conversion is expected to be completed in the second quarter of this year.
SPFT said that it will continue providing high quality,
recycled content newsprint for the west coast market from
the mill’s PM6.
“This project reflects the strategy to grow our packaging
business while remaining a preferred newsprint supplier
in the West,” said Allen Byrd, SPFT’s CEO. “Newberg is a
solid asset with great people. We are very excited about this
expansion of our packaging business in the West.”
6
expected to be achieved during the first 18 months after completion of the transaction.
Dave Paterson will lead the combined organization.
Under the terms of the deal, NewPage’s equity holders will
receive total cash and debt consideration of $900 million, consisting of $250 million in cash, most of which will be paid to
the stockholders as a special dividend prior to closing and the
remainder of which will be paid at closing, and $650 million of
new Verso first lien notes to be issued at closing.
NewPage’s equity holders also will receive shares of Verso
common stock representing 20% (subject to potential adjustment up to 25% under certain circumstances) of the outstanding
shares as of immediately prior to closing. Certain of NewPage’s
stockholders owning a majority of the outstanding shares of
NewPage common stock have agreed to vote their shares in favor
of the approval of the transaction.
Verso will finance the acquisition through $750 million in
committed financing, which will be used to pay the cash portion
of the merger consideration and to refinance NewPage’s existing
$500 million term loan prior to closing.
The value of the transaction is $1.4 billion, composed of the
cash consideration, the $650 million of new Verso first lien notes,
the Verso common stock and the refinancing of NewPage’s $500
million term loan.
Fox River Fiber Begins Use of Wastewater
Pre-treatment Facility
Fox River Fiber announced that it has
begun utilizing a $7 million wastewater pre-treatment facility designed to
reduce the company’s environmental
impact from its pulp manufacturing
operations.
The De Pere, Wisconsin-based
pulp manufacturer utilizes postconsumer fiber as its primary raw
material for making high-quality pulp.
According to the company, the on-site anaerobic digesting
system creates cleaner industrial wastewater prior to releasing it
to the Green Bay Metropolitan Sewerage District.
Fox River Fiber said that it plans to sell the recovered biological solids to other anaerobic treatment facilities for use as seed
in treatment towers.
industry news
NORTH AMERICA
Resolute to Indefinitely Shutdown the Last
Paper Machine at Fort Frances Mill
Resolute Forest Products has
announced the indefinite shutdown
of the last operating paper machine
at its mill in Fort Frances, Ontario
by the end of January.
The measure will, in effect, shutdown the entire mill.
Some 150 workers will be
impacted by the decision.
Late in November of 2012, Resolute shutdown the kraft
mill at Fort Frances, which has an annual production capacity of
approximately 200,000 metric tons of market pulp, and PM5,
which has an annual capacity of 105,000 metric tons of groundwood specialty printing papers.
According to a CBC news report, Resolute attributed this latest shutdown as the result of poor market conditions, although
company president Richard Garneau said the paper machine will
be kept ready for future operation.
In the meantime the company said it is looking for alternative
products for its Fort Frances operation, especially related to the
pulp mill.
RockTenn Acquires NPG to Expand Retail
Innovation and Solutions
RockTenn in early-January acquired NPG, Inc., a leading independent merchandising displays company.
Headquartered in Chattanooga, Tennessee, NPG provides
a broad range of display products and services to many of the
world’s most recognized retailers. NPG employs approximately
400 co-workers and operates two manufacturing facilities in
Chattanooga and one in Las Vegas, Nevada.
“NPG’s focus on retailers, their innovative retail solutions
and large-format printing capability expands our customer base
and significantly improves RockTenn’s ability to provide retail
insights, innovation and connectivity to all of our customers,” said
Craig Gunckel, executive vice president, RockTenn, and general
manager, RockTenn Merchandising Displays.
NPG will operate as RockTenn Retail Solutions.
Phil Harris, formerly chief executive officer of NPG, has been
named vice president and general manager, RockTenn Retail
Solutions. Harris will continue to manage the operations along
with his current leadership team.
“NPG is a strong strategic fit for us that will strengthen our
display business,” said Steve Voorhees, RockTenn’s chief executive officer. “I am excited to have the NPG team join RockTenn
and look forward to supporting their continued success.”
NPTA Presents 2014 Stanley O. Styles
Industry Excellence Award to
Don and Max Clampitt of Clampitt Paper
The National Paper Trade Association
(NPTA) announced the recipients of its
2014 Stanley O. Styles Industry Excellence
Award — NPTA’s highest honor. For the
first time in the award’s 30-year history, it
will be presented to two industry leaders,
Don and Max Clampitt of Clampitt Paper.
Don Clampitt
“Over the years, there are only a very
few whose names are synonymous with the merchant and
paper business. Clampitt is one of those rare names,” said
Tom Gallager, President of West Linn Paper Company. “Max
Clampitt was a leader in every regard.”
Max Clampitt was born in 1912 in Ruston, Louisiana and
founded Clampitt Paper with his wife, Mary-Nell, in 1941.
“Max Clampitt was a force in the merchant community,”
said James C. Tyrone, EVP of Commercial Operations and
Business Development, NewPage Corporation. “He built a
highly reputable and successful merchant business from the
ground up. Don continued with the same focus on customers that Max did.”
Don Clampitt began his 34-year career in the paper
industry working in the warehouse of Clampitt Paper during
high school. He returned to the firm after graduating from the
University of New Mexico and since that time has worked in
almost every position in the company. When Max passed
away in 2001, Don stepped into the President and CEO role.
“In a time when paper is too often reduced to a commodity, Don still loves to talk about what makes paper,
particularly premium paper, unique,” said Tom O’Connor,
Chairman and Chief Executive Officer of Mohawk. “He
pioneered the establishment of a Creative Center where
designers and printers can come look at samples and talk
about their work. Don is the only CEO of a major paper distributor I know of who still loves to go out and teach paper
classes for customers and design students.”
In addition to launching the Clampitt Creative Center in
2004, Don has grown the Clampitt brand to include 15 retail
stores and six warehouse locations and expanded to Tulsa,
Albuquerque and Kansas City.
Don Clampitt noted, “My father was the true visionary
behind Clampitt Paper, and I am honored to be considered
with him as a recipient of this award.”
Don Clampitt will accept the Stanley O. Styles Industry
Excellence Award on behalf of himself and Max at the
Paper2014 convention, March 23-25 in New York City.
7
industry news
NORTH AMERICA
ASPI Recognizes Kapstone’s Paul Duncan
with Excellence in Leadership Award
FPInnovations and Kruger in Joint Project to
Build Cellulose Filament Demonstration Plant
The Association of Suppliers to the Paper
Industry (ASPI) has named Paul Duncan
as the recipient of its 2014 Excellence in
Leadership Award. Duncan serves as mill
manager at KapStone Paper and Packaging’s
Longview Mill in Longview, Washington,
Paul Duncan
where he is responsible for managing all of the
manufacturing, maintenance and support operations of the mill.
“The Longview mill’s turnaround has been an incredible
achievement for everyone involved, and Paul Duncan has been
a big part of that change,” said ASPI President Carl Howe, vice
president sales for Kadant Paperline. “His professionalism, his
technical knowledge, and the example he sets for his employees
all deserve to be recognized and applauded.”
As mill manager, Duncan played a critical role in the recent
transformation of the Longview mill, which resulted in a production increase of 39% between 2007 and 2012. He also played a
key role in improving the mill’s safety culture, and was named
“Safety Manager of the Year” at the Western Pulp and Paper
Workers Conference in 2012.
ASPI’s Excellence in Leadership Award honors unique and
creative leadership of employees, company and key suppliers
through major projects or ongoing relationships. ASPI accepts
nominations from its members, and the Board of Directors votes
to determine the recipient.
Duncan is scheduled to accept the award at the ASPI 2014
Spring Meeting, which will be held February 26-28, 2014 in
Sarasota, Florida.
FPInnovations and Kruger Inc. have announced a joint project
to implement the world’s first five ton/day cellulose filament
demonstration plant at Kruger’s Trois-Rivieres Paper Mill.
The research and innovation project represents investments
totaling $43.1 million, including funding from Natural Resources
Canada, through the Investments in Forest Industry Transformation
(IFIT) Program, as well as a grant from the Quebec Ministry of
Natural Resources, a loan from Investissement Quebec, a contribution from Kruger Inc. and funds from FPInnovations’ pulp,
paper and bioproducts industrial members.
“A highly innovative wood-fiber based biomaterial, cellulose
filaments (CF) are expected to have an immediate impact on
Canada’s forest industry due to their capacity to be integrated
into other materials and to their high strength, light weight and
flexibility,” FPInnovations said. “CF will be used in a wide range
of applications as a lightweight strengthening additive to produce lower cost commercial pulps, papers, packaging, tissues and
towels.”
According to FPInnovations, the potential initial market for
CF as a strength reinforcing agent for traditional pulp and paper
products is conservatively estimated at 120,000 tons per year in
North America alone. In addition, a similar-sized, non-traditional
market is forecast for thermoplastics, reinforced plastics, thermosets, adhesives, and non-woven fabric and coatings, representing
a total revenue potential of $500 million per year for companies
that make use of CF.
Ahlstrom Completes Sale of Its West
Carrollton Plant
Ahlstrom has sold the converting operations of its West Carrollton
plant in Ohio to West Carrollton Parchment and Converting Inc.,
an Ohio-based family-owned company.
The parties have agreed not to disclose the value of the deal.
Under the terms of the deal, Ahlstrom sold its vegetable
parchment converting assets and related order book to West
Carrollton Parchment and Converting. The approximately
70 employees at the plant will transfer to West Carrollton
Parchment and Converting.
As part of the sale, Ahlstrom and West Carrollton Parchment
and Converting will establish a long-term supply agreement
for vegetable parchment paper, which is primarily used in food
packaging.
8
INDIA
Andhra Pradesh Paper Mills Changes
Name
International Paper announced that the name of its group
company, The Andhra Pradesh Paper Mills Limited (APPM),
has been changed to International Paper APPM Limited,
effective Dec. 16, 2013.
The company currently operates through two paper
mills at Rajahmundry and Kadiam in Andhra Pradesh under
APPM’s name.
“The new name recognizes the parentage of International
Paper while maintaining the link to the history of the
APPM brand,” explained Michael Amick Jr, President, IP
India and Executive Chairman, International Paper APPM
Limited.
industry news
EUROPE
CEPI Director General Teresa Presas to Step
Down, Marco Mensink Named Successor
After 10 years at the helm
of CEPI, the Brusselsbased
Confederation
of
European
Paper
Industries, Teresa Presas
has decided to leave the
organization at the end of
Teresa Presas
Marco Mensink
May this year. In the coming months she will ensure a smooth transition of the leadership
of CEPI to her designated successor Marco Mensink, who has
already worked with Presas as CEPI’s Deputy Director General
for the last two years.
Presas commented, “It has been ten years of an enriching
experience and of relentless work. In the last years, we have
consolidated our organization, successfully defended its interests
and laid out our long-term vision for the sector in the CEPI 2050
Roadmap.
“The coming years will be about implementation at the
different levels, including the progression of the breakthrough
concepts that came out of the Two Team project. Therefore, it is
a good moment for me to leave the organization and move on to
another life. I wish my colleague and successor Marco Mensink
every success in the future,” Presas concluded.
Domtar Completes Acquisition of Spain’s Indas
Domtar on Jan. 2 closed the acquisition of privately-held
Laboratorios Indas, SAU (“Indas”), pursuant to a definitive agreement announced on November 19, 2013.
Indas is Spain’s largest manufacturer and marketer of branded
adult incontinence products, with its IncoPack and Indasec line
of products.
Domtar acquired all the outstanding capital stock for EUR285
million and the business was expected to have about EUR140
million of debt, net of cash, at closing. Prior to the closing,
Domtar explained, “the net debt is expected to be reduced by
the collection of approximately EUR25 million of past due
accounts receivable before year-end or early 2014, resulting in
an enterprise value of EUR400 million. The majority of the debt
will be repaid by Domtar in connection with the closing of the
transaction.”
John D. Williams, President and CEO of Domtar, commented,
“The acquisition of Indas advances our transformation into a
leader in Personal Care, an attractive market segment that is
an important growth engine for Domtar. With the addition of
the new business, Domtar will become one of the leading adult
incontinence products manufacturers in Europe.”
Double A Agrees to Buy Pulp Mill in Alizay
Thailand-based pulp and paper producer Double A said that on
December 17 it agreed to acquire the pulp mill and bio-mass
power plant that is situated next to the site of its Alizay paper
mill in France.
Terms of the deal were not disclosed.
Double A is buying the pulp mill from the Department of
Eure in Northern France.
Jean Louis Destans, Chairman of the General Council of the
region of Eure, said, “We have agreed on the selling price of the
land, the buildings and the assets necessary to revive the production site. All that remains is for us to prepare and sign the deeds
as soon as possible. This is in both parties interest as it will initiate the revival of paper pulp production on the site.”
On January 23, 2013, the Department of Eure bought the
property and production assets of the Alizay pulp and paper mill
site from Metsa Board for EUR 22 million. On the same day, the
Department sold the paper mill to Double A for EUR 18 million.
Double A said the investment in the pulp mill will also
include investment in the site’s bio-mass power plant.
Thirawit Leetavorn, Senior Executive Vice President of
Double A, noted, “2013 marked a successful return of the Alizay
Paper Mill, which returned to full production in June and was
producing premium quality Double A paper by August. The mill
began exporting paper in September to the UAE and Eastern
Europe.”
Double expects to restart the pulp mill in the first quarter of
2015.
SOUTH AMERICA
Suzano Starts Up New 1.5 Million TPY Pulp
Mill in Maranhao
Suzano Papel E Celulose S.A.
recently started up operations
at its new pulp production unit
located in Imperatriz, Maranhao,
Brazil.
The first bale of pulp was produced on December 30 with FSC certification, Suzano said.
The new pulp mill will have eucalyptus market pulp production capacity of 1.5 million tons per year and surplus power
generation of 100 MW
Suzano said mill personnel are now focused on effectively
executing the ramp-up period to ensure an adequate learning
curve.
Suzano expects the pulp mill to produce about 1.1 million
tons in 2014.
9
industry news
SOUTH AMERICA
Fibria Continues Feasibility Studies on
Expansion of Tres Lagoas Pulp Mill
Fibria announced that it is
continuing with the feasibility studies for the expansion of its pulp mill in Tres
Lagoas (Mato Grosso do Sul
State), Brazil. The company
met with approximately 150
representatives of the main
36 equipment supplier companies of the pulp industry in the interior of São Paulo state.
“The idea behind the meeting was to invite [the representatives] to participate in the detailing stage of the project, which
should be submitted to the approval of the Board of Directors by
the end of the first half of this year,” Fibria explained.
Fibria’s new pulp line in Tres Lagoas, which already has
environmental licensing, and, if installed, will have a capacity
1.75 million tons per year, would increase the mill’s total pulp
production capacity to 3.05 million tons per year, making it the
largest pulp industrial unit in the world.
Fibria said that it is making every effort to take advantage of
a window of opportunity for the start-up of its new pulp capacity, and that it already has a major portion of the wood supply
needed for the new plant’s operations.
Fibria expects the new line to begin operations at the end of
the fourth quarter of 2016.
The Tres Lagoas mill opened on March 30 2009 and has a
bleached eucalyptus kraft (BEK) pulp production capacity of 1.3
million tons per year. The mill is self-sufficient in energy, using
biomass from eucalyptus and black liquor used in the industrial
process.
Norske Skog and CellMark Agree to Paper
Distribution Deal in Asia
Norske Skog and CellMark AB have entered a long term marketing agreement for sales of publication paper in the Asian
markets and established a new distributor in Singapore, NorCell
Asia, which holds exclusive marketing rights for all Norske Skog
products to be sold in the Asian markets.
Norske Skog is transferring its current sales operations and
sales staff in Singapore from PanAsia Paper Trading to NorCell
Asia.
Norske Skog plans to release about USD 15-20 million in
working capital by the cooperation with CellMark in the Asian
markets.
10
I N D U S T RY S U P P L I E R S
Minerals Technologies to Build Satellite
PCC Plant for UPM in China
Minerals Technologies has signed an agreement with UPM
to build a satellite precipitated calcium carbonate (PCC)
plant on-site at UPM’s paper mill in Changshu, China,
located in Jiangsu province. The satellite plant will provide
PCC — a specialty pigment for filling and coating highquality paper — to the mill and have an initial capacity of
100,000 short tons.
“We are extremely pleased that UPM, a premier global
papermaker, has chosen Minerals Technologies’ PCC for
their paper-filling needs at their mill in Changshu,” said
Robert S. Wetherbee, CEO of Minerals Technology. “This
is our fourth satellite agreement in China within approximately one year, bringing our total to seven in that country.”
The plant is scheduled to begin operation early in 2015.
Wuhan Chenming Starts Up Valmetsupplied Tissue Line in China
A new tissue line
delivered by Valmet
(formerly Metso
Pulp, Paper and
Power) successfully
came on stream at
Wuhan Chenming
Hanyang Paper Co.
Ltd’s mill in Wuhan, China, in November 2013. This is the
customer’s first tissue line, Valmet said.
According to Valmet, the new Advantage DCT 200HS
tissue line started up ten days before the estimated time and
is now producing high quality tissue at high speed. With a
width of 5.6 meters and an operating speed of 1,900 m/min,
the new production line will produce 60,000 tons a year of
high-quality facial, toilet and towel grades.
The raw material for the new line is virgin pulp,
Valmet said.
The delivery comprised a complete production line with
stock preparation equipment and an Advantage DCT 200
HS tissue machine including an OptiFlo II TIS multi-layer
headbox, a cast alloy Yankee cylinder, an Advantage AirCap
hood, an Advantage WetDust dust management system and
an Advantage SoftReel reel.
The delivery also featured Valmet’s patented Advantage
ViscoNip pressing technology.
industry news
India’s Printers at Odds with Paper
Producers’ Price Hikes
India’s paper and board manufacturers in 2013 pushed through
substantial price hikes that they say were necessary to offset rising input costs, while the region’s printers have watched their
profit margins shrink to unacceptable levels.
According to a report in PrintWeek (India), paper and board
producers in fiscal 2013 increased prices by 10 – 15%, and some
cases as much as 20 – 30%. The papermakers attribute the price
hikes to the increasing cost of domestic wood as well as imported
materials such as pulp and coal, due to Rupee’s depreciation.
“Paper mills are importing pulp wood, even if it is costlier
by 30 - 40%, as domestic stocks are scanty. JK Papers cites the
reason for this to be a disease outbreak that hit tree plantations
in Andhra Pradesh three years ago; and because of this, the
gross tonnage of wood availability has taken a nosedive. Though
companies have stepped up farm forestry, it will take another
couple of years before normalcy can be restored,” explains Anand
Srinivasan, author of the PrintWeek report.
In addition, India’s papermakers will have to deal with a
reduction on import duties in 2014. “The domestic paper industry, which is struggling to cope with high input costs and chronic
shortage of wood pulp, will face a new challenge in 2014 – dutyfree import of paper from Southeast Asian countries,” said Anand
Srinivasan, author of the PrintWeek report.
However, India’s printers are unsympathetic and say the frequent price increases come without warning. In an open letter
to the chairman of the Competition Commission of India (CCI)
in New Delhi, the Sivakasi Master Printers’ Association (SMPA)
called on CCI to take action against the paper mills that would
stop what has been termed “unfair trade practice” and substantially reduce the arbitrarily increased prices, as well as to direct
the mills to maintain prices at least for a period of four months.
“The print industry needs to be protected from the clutches
of paper mills which are into the process of making print industry a scapegoat at the altar of price increase, leading to the question of survival in the future,” SMPA wrote.
Domestic printers point out that many have annual contracts
with their customers and are unable to pass along the increases.
“The price has increased twice or thrice in the last two quarters
of 2013, taking the landed prices up by 20–30%. It has hit the
bottom line, as the cost cannot be passed on to the customers in
near terms,” said Vasant Goel, Director, Gopsons Papers, one of
India’s largest integrated print houses.
For now, Srinivasan says, many printers are resorting to buying
from cheaper mills or considering importing paper stocks despite
the Rupee’s depreciation.
Paper2014 to be held at the
New York Palace Hotel, March 23-25
The American Forest & Paper Association (AF&PA) and
NPTA Alliance announced that Paper2014 will be held at
the New York Palace Hotel, March 23-25, 2014.
Paper2014 is the premier annual paper industry
business convention, providing leading executives from
across the industry with engaging sessions and unparalleled networking opportunities.
The New York Palace, located on Madison Avenue,
is newly renovated and will provide a stunning venue for
networking in addition to being convenient to Midtown
Manhattan restaurants and attractions.
Paper2014 and the New York Palace offers:
•Single location for meetings and programming that will
maximize networking opportunities
•New for 2014! – Larger Tower Corner suite option is
more than twice the size as previous hotels for
entertaining up to 50 people.
•Best space, most amenities, with the greatest value
for rooms and suites in midtown
•New for 2014! – Complimentary WiFi in guest rooms
and suites
•New for 2014! – Dedicated hotel banquet staff to
service your meeting needs
Paper2014 Suites
Official Paper2014 Suite holders will maximize visibility
and strengthen relationships with customers, suppliers,
manufacturers, publishers and distributors of printing
paper, packaging material and industry suppliers.
Pre-reserve Your Suite Today
Suites sell fast and are being offered on a first come, first
served basis. Take advantage of this great value before
all suites are sold by contacting Nicole Boland by email
at: [email protected] or call (312) 673-5828.
Paper2014 is hosted by the American Forest & Paper
Association and NPTA.
11
people
PA P E R
n
Ahlstrom announced that Sakari Ahdekivi
has been appointed Chief Financial
Officer and member of the company’s
Executive Management Team. He will
join Ahlstrom on February 1. Prior to
Ahlstrom, Ahdekivi was Managing
Director at Tamro Finland and Baltics.
n
Twin Rivers Paper Company announced that Tony
Rigelman has joined the company as Vice President, Sales.
Rigelman has over 19 years of industry experience in a
variety of leadership roles, serving most recently as Director
of Sales for Technical and Specialty Papers at Domtar.
Sakari Ahdekivi
n
Appvion announced that
Matt Denton has been
appointed Senior Vice
President and General
Manager of the company’s carbonless and
Jason Schulist
Matt Denton
security papers business;
and Jason Schulist has joined Appvion as Vice President
of Continuous Improvement.
n
Atlas Paper Mills has named Jim Brown as Chief
Executive Officer. Brown succeeds Joe Tadeo, who left
the company to pursue outside interests. Brown most
recently served as an Executive Vice President at Duro
Bag Manufacturing Company.
n
Greif has appointed Peter Watson as
Chief Operating Officer of the company.
Watson was group president responsible
for Greif’s Paper Packaging and Land
Management business segments as well
as Global Sourcing & Supply Chain and
the company’s Greif Business System
capabilities.
Peter Watson
Mac Papers has named Craig Boortz as the new Vice
n
President and Regional Manager. He succeeds Steve Bethea,
who is retiring after more than 42 years with the company.
In a related move, David McGehee, Jr., succeeds Boortz’s as
General Manager in Greenville, SC.
n
PaperWorks Industries has named William McSwain as
interim President and CEO, replacing Mark Staton, who
departed in January. McSwain is a seasoned business
executive with leadership experience in many industries.
n
Rayonier has elected Lynn Wilson to the position of
Executive Vice President, Forest Resources. Wilson is a
member of Rayonier’s senior management team and is
responsible for 2.6 million acres of timberland in nine
states and New Zealand.
12
INDUSTRY SUPPLIERS
n
Ashland Water Technologies has hired
Jeff Fulgham as vice president, marketing. He most recently served as chief
sales and strategy officer for Banyan
Water, based in San Francisco.
n
OASIS Alignment Services has named
Brian J. Hiltunen as President. He
succeeds Ray Masse, who will continue
as Chairman of the Board. Previously,
Hiltunen served as Vice President and
General Manager for OASIS.
Jeff Fulgham
n
Thiele Kaolin Company recently
Brian Hiltunen
announced the following changes within
its sales leadership: Eric Tillirson has been promoted to
Senior Vice President and Director of Sales Development;
Mike Markillie has been promoted to Director of World
Wide Sales and Technical Service; Scott Ahrens has
been promoted to North American Sales Manager; and
Tom Bennett has been promoted to Sales and Marketing
Manager.
I N D U S T R Y- R E L AT E D
n
The Confederation of European Paper
Industries (CEPI) has appointed Gary
McGann as its new Chairman. McGann
is Group CEO of Smurfit Kappa. He
succeeds outgoing chairman, Jussi
Pesonen, the President and CEO of UPM.
Gary McGann
n
University of Maine alumna Carrie Enos
has been named president of the
University of Maine Pulp & Paper
Foundation. She replaces Jack Healy ‘74,
who has held the position since 2007
and is retiring this spring. Enos has
Carrie Enos
worked in the paper industry since 1997,
most recently in the position of finished products business
unit manager at the Verso Paper Mill in Bucksport.
calendar
FEBRUARY 3-6, 2014
Paper Week Canada - 100th Anniversary
PAPTAC
Fairmont Queen Elizabeth Hotel
Montreal, Canada
www.paperweekcanada.ca/
JUNE 3-5, 2014
PulPaper 2014
Adforum
Helsinki Exhibition & Convention Centre
Helsinki, Finland
www.pulpaperevent.com
FEBRUARY 11-12, 2014
Forest Products Investment Conference
RISI
Grand Hyatt New York
New York, New York, USA
www.risiinfo.com/events
June 22-25, 2014
71st Pulp and Paper Safety Conference
Pulp and Paper Safety Association
Renaissance Vinoy Resort
St. Petersburg, Florida, USA
www.ppsa.org
FEBRUARY 26-28, 2014
ASPI Spring Meeting
Association of Suppliers to the Paper Industry
Ritz-Carlton
Sarasota, Florida, USA
www.aspinet.org
MARCH 18-21, 2014
Tissue World Americas
UBM Asia Trade Fairs
Miami Beach Convention Center
Miami, Florida, USA
www.tissueworld.com
MARCH 23-25, 2014
Paper2014
AF&PA and NPTA
New York Palace Hotel
New York City, New York, USA
Contact: Nicole Boland (NPTA)
[email protected]
June 22-26, 2014
60th IEEE Pulp and Paper Industry
Conference
Institute of Electrical and Electronics
Engineers
Atlanta Marriott Buckhead Hotel
Atlanta, Georgia, USA
www.ieee.org
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APRIL 2-4, 2014
Spring Outlook and Strategies Conference
Paperboard Packaging Council
Royal Sonesta Hotel
New Orleans, Louisiana, USA
www.ppcnet.org
APRIL 27-30, 2014
PaperCon
TAPPI
Nashville Convention Center
Nashville, Tennessee, USA
www.papercon.org
MAY 4-7, 2014
International Pulp Week
Pulp and Paper Products Council (PPPC)
The Drake Hotel Chicago
Chicago, Illinois, USA
www.internationalpulpweek.com
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13
market grade
Capacity Bulge, Sluggish Demand Remain
Challenges for Containerboard Market
2013 wasn’t a bad year for containerboard mills but results were
decidedly mixed. Price increases were enacted on board and corrugated
boxes in early 2013 that boosted margins, but underlying box demand was stagnant.
2014 offers hope that improved economic growth can propel box demand to stronger
gains, but the impact of new containerboard capacity remains a nagging concern.
By Harold M. Cody
O
OCC costs and a long term
ver the course of the
over supply situation in the
last 12 months the
box market. The increase
containerboard induswas successful mainly due to
try was characterized by
the sweat and hard work on
relatively weak fundamenthe part of board producers
tal demand for corrugated
who took significant marketcontainers and rising capacrelated downtime to keep
ity. However, despite these
inventories under control
negative trends, the overall
and the market balanced.
business benefitted from an
At the end of the year and
approximate $100/ton price
into early 2014, prices are
increase in major containerreported to have held mainly
board grades and an increase
steady despite somewhat
in box prices as well. The
weak box cut ups during the
biggest concern entering
seasonally slow months of
2014, other than the basic
the year again due to downstrength of the global econSignificant new capacity came online in the
time
that sustained operating
omy, is the impact of a surge
second half of 2013. This includes tonnage
rates.
in new capacity, which could
from the startup of Norampac’s new 330-inch,
As noted, OCC costs fell
throw a monkey wrench into
525,000 tpy recycled linerboard machine at the
steadily from a peak almost
the works.
Greenpac mill in Niagara Falls, New York.
$180/ton in late 2011 before
The rise in prices and a
bottoming out at about $100/ton in early 2013. Since then,
muting of input costs — at least for a while as OCC prices
prices have posted a modest rebound but remain low. Many
fell to very low levels earlier in 2013 — were certainly
observers believe that as global containerboard demand
noteworthy developments last year in the containerboard
accelerates in 2014, OCC prices will surge and this may promarket. In April, a $50/ton increase was successfully passed
vide the impetus for prices to also rise further on liner and
on to converters that raised linerboard prices to about the
medium grades this year.
$650/ton range. This was the second successful increase in
U.S. box and containerboard data through November
an eight-month period, following a $50/ton increase that
2013 clearly demonstrate the impact of sluggish economic,
was enacted in September 2012. These increases significjob and personal income growth on the box market. For the
antly improved operating margins for the major producers.
first 11 months of 2013, box shipments were down 0.5%
Containerboard mills were able to push through the
vs. the prior year at 331.2 billion square feet year-to-date,
increases despite several important indicators that wouldn’t
and down 2.5% vs. November 2012 levels. On an average
seem to support an upward movement in prices, i.e. weak
week basis, which accounts for a different number of shipdomestic demand for corrugated boxes, a steady decline on
14
market grade
ping days month to month, November box shipments were
up 2.6%, according to FBA and AFPA data. Total containerboard production, at 31.9 million tons, was up 1.6% over
the first eleven months vs. the prior year level, but down
4.5% in November vs. last year.
Export Markets Cooled in 2013
The export market continues to be an important market for
U.S. mills, with linerboard exports through November at
3.5 million tons according to AF&PA. However, this is down
0.6% vs. 2012 levels. While demand in some export markets
has weakened the drop is also partly due to mills in North
America diverting tonnage to domestic markets. The export
market has appeared to be weak in recent months, with
export prices reported to be down in Europe and weak in
Latin America. The weaker pricing is a result of a slowdown
in demand plus an excess of supply in several regions including North America and Europe.
U.S. Bureau of Census data through the first three quarters of 2013 showed U.S. Kraft linerboard exports down
6.3% at 2.8 million tons vs. the same period in 2012.
Exports to the largest U.S. export market, Western Europe,
were off nearly 20% at 585,000 tons. Exports were also
down significantly to Canada, while smaller drops were
posted for Mexico, the Middle East and Africa. In contrast,
exports to Central America and South America, at 438,000
tons and 439,000, were up by 3.6% and 11%, respectively,
vs. 2012 levels. In turn, export prices are reported to have
slipped as well in Europe and were under pressure in the
fourth quarter in Latin America.
New Capacity a Concern
As noted, significant new capacity came online in the second half of 2013 that is a cause for concern, but reportedly, so far, it hasn’t had a severe impact on the market.
This includes tonnage from the startup of Norampac’s
new 330-inch, 525,000 tpy recycled linerboard machine
at the Greenpac mill in Niagara Falls, New York and the
conversion of two newsprint machines to containerboard.
This includes the addition of 150,000 tpy of linerboard by
SP Fiber in Dublin, Georgia, and 300,000 tpy by Atlantic
Packaging in Whitby, Ontario.
The converted paper machine in Dublin has a 390,000
tpy capacity, but the net gain is 150,000 tpy because of
switching another machine at the mill from board to newsprint. Combined, the new machine and conversions added
nearly one million tons of new capacity. All three machines
came online in the 2nd and 3rd quarter of 2103. The impact
of this tonnage, much of which was just beginning to hit the
market late in 2013, is a major concern in 2014. Pratt also
announced plans to build a 360,000 tpy containerboard mill
by its box plant in Valparaiso, Indiana.
Box Demand and Consumer Spending
Probably the biggest unknown in the outlook for containerboard is box demand. The reasons behind the relatively
poor performance recently in box demand is fairly obvious: a sluggish U.S. economy in combination with weak job
growth and poor growth in personal income resulted in
weak growth in consumer spending. This is particularly true
for key markets that consume a lot of corrugated board such
as food and beverage. With sluggish or no growth in disposable income over the last few years, consumers spent less on
packaged food and beverages. These uses are critical for box
plants as they account for just under half of total U.S. box
shipments. Major food companies also reported lackluster
results, mirroring the poor performance of corrugated boxes.
Looking Ahead
Looking forward into 2014, there is hope that the U.S. and
European economies will perform better than they did in
2013, and this could provide a modest boost in box demand.
Many economists believe that the U.S. economy could
expand at closer to a 4% rate this year vs. weaker growth
pegged at about 3% in 2013, which is coming on the heels
of 2.8% and 1.8% growth in GDP in 2011 and 2012, respectively. Similarly, Europe’s GDP fell in 2012 and was expected to post little or no gain in 2013. However, projections
call for modest growth in the Euro area economy in 2014.
Notable structural changes in the containerboard market in recent years, and which continued in 2013, will also
likely impact the market’s supply and demand balance as
well as the direction of pricing. Major mergers and acquisitions, including two major ones in 2013, have resulted
in the top five containerboard producers now accounting
for 75% of U.S. capacity. The most recent deals closed last
year include Kapstone’s $1 billion acquisition of Longview
Fibre and PCA’s $2 billion acquisition of Boise. Kapstone’s
deal moved the company into the No. 5 position in North
American containerboard capacity, behind International
Paper, RockTenn, Georgia-Pacific and PCA.
A rebound in the U.S. economy and thus improved
box demand would be of great benefit to producers, who
wouldn’t have to continue to take downtime and also would
result in higher operating rates. It would also go a long way
in accommodating the recent capacity that has been added
and allow producers to maintain a more balanced market.
Given the recent weakness and new capacity it’s unlikely any
major movement in prices can be expected early this year.
However, if the U.S. and global economy improves, and
input costs such as for OCC begin rising, producers are
likely to seek additional increases later in 2014. n
Harold Cody is a contributing writer for PaperAge. He can be
reached by email at: [email protected].
15
heads up
Quiet Start in Europe
The European paper industry is off to a relatively quiet start in 2014,
and industry observers say the year may continue as such, which
may be a good thing.
By David Price
I
t’s hard to spot unless
industry. The consequences
you’re a chemist in an
could have been devastating.
industry lab, where there’s
Paper recycling in Europe
a lot happening in cellulose
would have dropped from 47
and nanotechnology. Or if you
million tpy to 37 million tpy,
build with wood you’re doing
leading to mill closures and the
well here in Europe. I condisappearance of hundreds of
tacted the top five European
recycling operators.
pulp and paper companies,
In a symbolic act in
spoke with two consultants,
September 2013, CEPI tempoand attended two major conrarily dumped bales of wasteferences (Hawkins Wright
paper in front of the EU’s
and European PaperWeek).
headquarters in Brussels to
The conclusion: not a lot is
draw attention to the problem.
happening. Yes, Domtar just
So now it’s back to the drawWaste paper or recycled? In September 2013,
completed its acquisition of
ing board to try and solve the
CEPI temporarily dumped bales of waste paper in
the Spanish personal care
problem of when does paper
front of the European Commission’s headquarters
products manufacturer Indas,
cease to be classified as waste?
building in Brussels to draw attention to the
and Double A of Thailand
It so happens that, at presEC’s proposal to redefine recycled paper.
(formerly Advance-Agro) has
ent in Europe, sourcing good
announced plans to restart the Alizay pulp mill that sits next
quality recycled fiber is becoming a problem, especially for
its paper mill in France, but that’s about it.
the tissue sector.
Bits and Pieces
Paper or Plastic?
Yet there is some significant and positive action in recycling, security papers and tissue. The industry has successfully lobbied the European Parliament to block a proposal
by the EU to reclassify wastepaper — the vote was 606
“for” and 77 “against.” This proposal would have classified
wastepaper as “recycled” even before it’s been recycled! The
vote in Strasbourg will save more than 20,000 ‘green’ jobs
in the industry and 140,000 indirect jobs in Europe. If this
legislation had passed it would have relaxed the EU’s waste
management rules and triggered a flight of wastepaper from
the EU to Asia, pushing up prices in Europe and undermining the quality of wastepaper available to the EU recycling
The Bank of England (BoE) has decided to replace British
bank notes with plastic (polymer) notes. The job was
expected to go to either De La Rue, the existing maker
of BoE notes, or Innovia, which manufactures most of the
polymer notes around the world. The Bank promised a consultation process last October but by January it was a done
deal with Innovia. The Bank has ruled out importing plastic
money from China.
Mark Carney, formerly the Governor of the Bank of
Canada, is now Governor of the BoE. While Governor of
the Bank of Canada he introduced in 2011 a change of
paper to plastic for $100 bills. Canada has since gradually
16
heads up
switched to plastic $50, $20, $10 and $5 bills.
They say a plastic bank note is tougher to counterfeit,
lasts longer and can be cleaned. But I also hear that vending machines must be upgraded in order to accept them.
Bottom line: the Bank of Canada says they’re here to stay. If
this is the future of bank notes in the UK, what will happen
to the traditional British printers and producers of security
papers? It will be a massive blow said one manufacturer
who did not want to be named. A consultant to the industry
told me it will be a big hit on this specialist sector, but it
will survive as De La Rue and others are major suppliers of
paper bank notes to countries all over the world.
The money and ownership trail of Innnovia is fascinating. It is an off-shore company and its owners plan to sell
it to Pamplona Capital Management, a fund backed by the
Russian billionaire, Mikhail Fridman. The Guardian newspaper commented, “If the Bank thinks it unacceptable for
British currency to be in Chinese hands, are Russian hands
any more acceptable?”
Reusable Diapers
Despite the biggest baby boom in the UK in 40 years, sales
of diapers have fallen nearly 4% in the last year. Sales of
Pampers (P&G), which dominates the UK market, have
fallen by 4.1% according to the trade magazine The Grocer.
The UK diaper market is worth $800 million a year and
Pampers sold 76.3 million fewer diapers last year despite its
biggest rival, Huggies (Kimberly-Clark), exiting the UK and
European market last October. K-C’s shock exit closed mills
in UK, Italy, Spain and Poland with the loss of 1500 jobs.
Consultants think the drop in sales is due to middle class
households doing their bit for the environment and families
switching from the big brands to cheaper diapers from the
discount retailers as household budgets shrink. Own-label
products are up by 37.3% and volume sales have risen 44.5%
But P&G, SCA and the Italians — with 7 million tpy of tissue production in Europe — seem unfazed by this trend.
I’m not convinced there’s a long term market for reusable
diapers. I think it’s fashionable and green and will not last.
If you think through the detail of cleaning, separating and
reusing a soiled diaper, the technical and hygienic issues are
considerable. And there is solid evidence the tissue makers
are rethinking their use of recycled fiber in their products
and are turning, increasingly, to virgin fiber. n
David Price is a contributing writer for PaperAge. He can be reached
by email at: [email protected].
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17
Easy-to-Apply
Dryer Performance
Indicators
Photo courtesy of Kadant Johnson Inc.
The dryer section is a large consumer of energy, but ensuring it is operating efficiently
is not difficult. By assessing only a few easily applied “dryer performance indicators”,
one can determine whether large improvement opportunity exists.
By Jeff Chaloux
D
ryer performance audits have been used for years as
part of efforts to optimize the papermaking process.
These audits involve quantifying dryer performance
indicators and comparing the indicators to performance
standards. Some of the traditional indicators are not easily
applied since they require special measurement techniques
and a highly experienced assessor. Others are easily applied
and are valuable to optimization efforts.
Five easily applied dryer performance indicators that
provide a good indication of dryer section energy efficiency
include:
• Hood exhaust humidity
• D
ryer section supply air flow relative to dryer section
evaporation load
• Dryer section supply air temperature
• E
nergy losses from the steam system relative to total
steam dryer steam consumption
18
• H
igh pressure motive steam consumption as a percent of
total dryer section steam consumption
Commonly applied standards for these indicators, the
reasoning behind the standards, and considerations related
to assessing the indicators are highlighted the following
discussion.
HOOD EXHAUST HUMIDITY
TAPPI standards specify the exhaust air drawn from the
dryer section hood be 0.04 to 0.07 kg w.v./kg d.a. (300 to
500 grains) for “open” type hoods, 0.13 kg w.v./kg d.a. (900
grains) for “medium humidity” closed type hoods with fully
enclosed basements, and 0.17 kg w.v./kg d.a. (1200 grains)
for “high humidity” closed type hoods. Operating a hood
with excess exhaust (and too low a humidity) lowers the air
temperature surrounding the sheet, dryers, and dryer fabrics.
It also increases the radiation and convection heat losses
and reduces the effectiveness of heat recovery equipment
energy efficiency – dryer section
Avg. Exhaust Humidity (kg w.v./kg d.a.)
installed on the hood exhaust sysMachine Production Rate (Metric TPD)
0.250
tems. Operating a hood with insufOpen Hoods
0.225
ficient exhaust positively impacts
Closed Hoods
energy efficiency, but it risks operaHIgh Performance Hoods
0.200
Recommended for High
tional problems such as dripping on
Performance Hoods
0.175
the sheet, corrosion of equipment,
0.150
and spillage of heat and humidity
to the machine room.
0.125
Recommended for Closed Hoods
Hood exhaust humidity can eas0.100
ily be assessed by inserting a wet
0.075
and dry bulb thermometer into
the hood exhaust flow stream. For
0.050
an accurate measurement of wet
Recommended Range for Open Hoods
0.025
bulb temperature, the air velocity
0.000
passing across the wet bulb should
0
500
1000
1500
2000
be greater than 3 m/s. Many dryer
sections operate with inappropriate Figure 1 – Measured Average Hood Exhaust Humidities on Active Paper Machines
amounts of exhaust. Figure 1 shows
(See TAPPI TIP 0404-24 for guidelines on calculating the
average hood exhaust humidities for several recently
evaporation load.) The total supply air flow rate to the dryer
measured operating paper machines.
section should be assessed with field measurements. For
most hot air supply systems, the best method for measuring
DRYER SECTION SUPPLY AIR FLOW RELATIVE TO
EVAPORATION LOAD
flow rate involves using a vane anemometer at the face of
The rate of hot air supply to the dryer section should be
air intakes.
appropriate for the rate of evaporation from the dryer secDRYER SECTION SUPPLY AIR TEMPERATURE
tion. If it is not, there is opportunity to save energy or
Assessing supply air temperatures for pocket ventilation
improve drying performance.
systems is normally easy. If online indication does not exist,
Most paper machines are operated with a heated supply
temperatures can be easily measured with a thermocouple
air system serving the dryer section. The delivery of heated
probe inserted into the supply air stream. The TAPPI recsupply air to the dryer section lowers the relative humidity
ommended supply air temperature for dryer section supply
of air surrounding the sheet and drying equipment. Nearly
air systems is 82 to 93°C. Temperatures significantly lower
all dryer sections that operate with no form of dryer section
than this range are usually inappropriate since they increase
supply air system are unfelted dryer sections that lack felt
risk of condensation, dripping, and corrosion of equipment.
rolls. On dryer sections with dryer fabrics, having heated
Temperatures significantly above this range are usually
supply air is normally necessary to avoid felt roll corrosion.
inappropriate since they significantly increase energy
TAPPI standards specify pocket air humidity be between
demand while providing little benefit.
0.12 to 0.28 kg w.v./kg d.a. For high-speed machines making
ENERGY LOSSES FROM THE STEAM SYSTEM
lightweight grades, excessive air supply to dryer pockets can
An energy efficient steam system operates with few losses.
negatively affect web stability. For machines that do not
By far, the easiest way to assess the energy efficiency of a
have problems with sheet flutter, it is suggested the air supsteam and condensate system is to quantify steam losses
ply to the dryer section target a humidity of 0.20 kg w.v./
from the system and compare them to total dryer section
kg d.a., which is the median of the recommended humidsteam consumption. Alternative methods of assessing steam
ity range by TAPPI. To achieve this pocket humidity, the
system energy efficiency, which include evaluating steam
amount of air that must flow into the dryer pocket is 4.2 kg
consumption per unit evaporation or steam consumption
d.a./kg evaporation.
per unit production, have clear shortcomings. Realize that
To assess the supply air flow rate per unit evaporation,
the waste steam flows that hurt steam system energy effiboth the dryer section evaporation load and the total supply
ciency are normally small relative to total dryer section
air flow rate must be assessed. The dryer section evaporation
steam consumption. When quantifying steam consumption
load can be quantified with a simple drying rate calculation.
19
energy efficiency – dryer section
Dryer Performance Indicator
Hood exhaust humidity
Dryer section supply air flow
relative to dryer section
evaporation load
Dryer section supply air
temperature
Energy losses from the steam
system relative to total steam
dryer steam consumption
High-pressure motive steam
consumption as a percent of
total dryer section steam
consumption
Recommended Level
0.04 to 0.07 kg w.v./kg d.a.
for an “open” hood
0.13 kg w.v./kg d.a. for a
medium humidity closed hood
0.17 kg w.v./kg d.a. for a
high humidity closed hood
5 to 7 kg d.a./kg w.v.
82 to 93°C
Total combined steam losses
less than 3% of total dryer
section steam consumption
4 to 8% of total dryer section
steam consumption
per unit evaporation, highly accurate information on steam
consumption and evaporation load are needed just to get a
rough indication of steam system energy efficiency.
An energy efficient steam and condensate system will
have total “losses” that equate to less than 3% of total dryer
section steam consumption. Following are the most prevalent
forms of energy losses from a steam and condensate system.
Venting from steam sections through automatic vent
valves. A well-designed steam system with properly functioning devices will vent no steam during “sheet on” conditions. Open vent valves during “sheet on” conditions generally indicate a steam system deficiency or equipment problem. If venting is occurring, the recommended technique
for quantifying the steam lost is a simple steam valve flow
calculation.
Steam losses to a condenser. Paper machine dryer sections with cylinders operating at low pressure are equipped
with one or more vacuum condensers. When assessing steam
system energy efficiency, the steam energy losses to the condenser are viewed as waste. This is even for cases where the
warm water from the condenser appears to be fully utilized.
For most paper machines there is potential to either reduce
the demand for warm water or to generate the required
warm water using a form of heat recovery.
The best technique for quantifying the steam energy
losses to a condenser measures the water flow rate with a
portable water flow meter and the inlet and outlet water
temperature. Modern “transient time” meters are well
proven for the suggested water flow measurement. An easy
method for assessing water inlet and outlet temperature is to
paint black “spots” on uninsulated portions of inlet and out20
let water piping, and to then measure the line temperature
with an infrared pyrometer.
Flash steam losses from Main Condensate Tank. A good
steam system is designed such that flash steam generated at
a main condensate collection tank is put to good use. Flash
steam losses to atmosphere should be completely avoided.
The best use of low-pressure flash steam is for any cylinders
being operated at low pressure. Another potential good
use for flash steam is at pocket ventilation supply units
equipped with flash steam coils. Yet another potential good
use for flash steam is at steam showers or steam boxes. If
flash is used for steam showers and steam boxes, appropriate
safeguards against condensate carry-over must be applied. A
realistic goal is to have no flash steam losses to atmosphere.
HIGH PRESSURE MOTIVE STEAM CONSUMPTION
A common type of steam system for paper machine dryer
sections is a thermocompressor type system. This system uses
high-pressure motive steam for recompressing blow-through
steam. For those mills that have steam-driven turbine generators, high-pressure steam is more valuable than turbine
exhaust steam. The high-pressure steam can be passed
through the turbine generator so that relatively inexpensive
thermal energy is converted to a more valuable electrical
energy. For mills with turbine generators, the paper machine
dryer section should draw as high a percentage as possible
of its total steam demand from headers being fed by turbine
exhaust and as little a percentage as possible from headers
being fed high-pressure steam that has not passed through
turbine generators, or has only partially passed through
turbine generators to an intermediate extraction point.
Potential methods for reducing motive steam consumption include:
• R
eplacing inefficient thermocompressors with properly
sized high-efficiency units.
• Upgrading rotary syphons to stationary syphons
• I mproving the accuracy of differential pressure transmitters so that differentials can be minimized.
• A
ctively managing differential pressures as a function of
machine operating conditions so that excessive differential pressures are avoided. This is best done through
application of supervisory control logic.
The dryer section is a large consumer of energy, but ensuring it is operating efficiently is not difficult. By assessing only
a few easily applied “dryer performance indicators”, one can
determine whether large improvement opportunity exists. n
Jeff Chaloux is a Senior Process Engineer for Kadant Johnson
Systems Division. He can be reached at: [email protected].
PAPER
Convention Daily
M
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Schedule of Events
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MOndAy, MARch 18, 2013
• 7:00a.m.–5:30p.m.
Paper2013 Registration
Paper2013 Convention
Daily Desks
P’13 Lounge
Moulin Rouge Room, Lobby
Level
3
A
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PAP
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Opportunities Abo
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David Scheible,
This year’s program
focuses on the opportuni
ties
in emerging markets, and
business and demographic
trends that affect the paper
kets, and business and demograph
ic
trends that affect the paper
and paper-based packaging industry.
Over the next two days,
company
suites are open so we can
check in
with key clients and suppliers
and
connect with existing and
potential
new business contacts.
Thank you for joining us
at Paper2013. We look forward to
sharing the
experience with you.
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water treatment
Microbiological Auditing and Control –
A New and Powerful
Approach to Controlling
Problem Organisms
A genetic-based technique used to detect and identify troublesome
microbes in paper mills’ fresh water systems has been found to be quick,
accurate, and less cumbersome than traditional methods.
By David Oppong and Tod Stoner
Editor’s Note: This article was first presented at PaperCon 2013.
F
resh water contamination of paper mill systems may
lead to outbreaks of deposits of filamentous bacteria
often collectively called “pink slime.” These deposits can
be difficult to treat with modern microbiological control
programs, especially in mills where corrosion is a concern.
We have adopted a methodology that uses DNA fingerprinting to identify problematic fresh water organisms. Once the
microorganism is isolated and identified, we can then use
our available biocidal actives to identify the most appropriate formulations so that the deposit can be effectively
treated. Even though problem organisms can manifest in
similar ways, specific problem organisms can vary widely in
the optimum product and MIC required to control them.
Thus, by utilizing the state of the art technology to identify problem organisms, we not only provide our customers
with some of the most advanced control chemicals, but the
resulting information is also entered into a database where
22
it can be retrieved to help identify and treat problems found
in other mills.
INTRODUCTION
The problems caused by uncontrolled growth of microorganisms in the production of paper are well known. These
include odor, paper stains, web breaks, slime, blockage of
1
pipes, and corrosion. Microorganisms enter the production system from a variety of sources such as raw materials,
water, soil, and air. The control of microorganism is usually
accomplished with the use of biocides and/or dispersants as
well as good housekeeping including boil out of the system
where appropriate.
In preparation for effective microbial control of a system,
a good audit of the system helps as this can give a picture of
the types, nature, and the relative abundance of the microorganisms that may be causing the problem. The use of the
water treatment
microscope, visual inspection, ATP assays, and also microbial
plate counts are some of the techniques frequently
employed in the auditing process.
tures using the instructions provided in the PrepMan Ultra
Sample Preparation Reagent Protocol (Applied Biosystems).
DNA methods for detecting and
Once DNA is obtained, a polymerase chain reaction
(PCR) is run. PCR is a method for amplifying or making
8
millions of copies of a particular gene sequence. In identifying eubacteria, the 16S rRNA gene is amplified. This
gene is used in the identification of most bacteria because
9
it is expected to occur in all bacteria. The 16S rRNA gene
is also conserved which means it has changed very little
over the evolutionary period. Additionally, the 16S rRNA
gene has regions of significant sequence variability that
allows bacteria of different species to be differentiated or
10
identified.
A PCR reaction mixture would include the template
DNA, primer set to initiate the reaction, thermostable DNA
polymerase, nucleotides (dNTP’s), magnesium, and a buffer.
All reagents and method for amplifying the 16S rRNA gene
are contained in the MicroSeq 500 16S rDNA Bacterial
Identification PCR Kit (Applied Biosystems).
At the end of the reaction, the success of the PCR is
checked by taking a sample of the reaction mixture and running agarose gel electrophoresis. If the expected band can
be visualized on the gel, the PCR is deemed to be successful
and the product is cleaned up of the unreacted reactants.
identifying microorganisms have
become increasing popular.
DNA methods for detecting and identifying microorganisms have become increasing popular. They have been used
2
3, 4, 5, 6, 7
and have
in the leather industry, pulp and paper
played significant roles in expanding our knowledge of the
microbial flora of these environments. It would be advantageous if some of these techniques could be incorporated
into microbiological auditing programs and routinely used
to detect and identify troublesome microbes in paper mills.
In this presentation, we describe a genetic-based identification technique that we have found to be useful and which
we frequently employ together with the other established
auditing tools when we initiate microorganism control in
a system. We also present the use of these techniques in
studying the “pink slime bacteria” in deposits from six
different mills.
SAMPLING AND ISOLATION OF BACTERIA
The first step in using DNA based auditing method involves
selection of sampling points. Typically, we obtain samples
from several points of interest including water and slime
deposits. Samples of slime deposits and incoming water
are collected and sent to the laboratory for microbiological
analyses. The samples are processed immediately after arrival
at the laboratory. Samples are aseptically processed by serial
dilution in sterile saline and plated on plate count agar, R2A
agar, Stokes agar, and actinomycetes isolation agar. The plates
are incubated at 30⁰C or 45⁰C-50⁰C (depending upon field
conditions) for 2-7 days and colonies picked, and re-streaked
to obtain pure cultures of bacteria. The isolation could also
be done by streaking the original samples onto appropriate
plates, but we usually use the serial dilution method as this
also affords us the chance to estimate the relative numbers
of bacteria that may be causing the problem.
DNA PREPARATION
The genetic method for the identification is based on the
MicroSeq system from Applied Biosystems, Foster City,
California. The method requires the use of DNA from pure
cultures of bacteria. The DNA is extracted from the cul-
GENE AMPLIFICATION
16S rRNA SEQUENCING AND DATA ANALYSIS
The cleaned amplified DNA is used in cycle sequencing.
DNA sequencing is a method that allows us to determine
the order or sequence in which the bases (A, T, G, C) occur
in a particular gene or DNA. Cycle sequencing utilizes four
different fluorescent dyes to covalently label the correspond11
ing bases in the DNA.
16S rRNA gene sequences of the isolates are generated
using the MicroSeq 500 16S rDNA Bacterial Identification
Sequencing Kit (Applied Biosystems). After cycle sequencing, the reaction mixture is cleaned up to remove unreacted
reactants and unincorporated dyes according to the method
provided by the manufacturer.
The reaction products from the cycle sequencing are then
electrophoresed on an automatic DNA sequencing machine.
Sequence analysis and bacterial identification are performed using Applied Biosystems’ MicroSeq microbial
analysis and database. In a case where there is no match, a
BLAST search of the GenBank or Ribosomal Data Project is
conducted for a possible match.
23
water treatment
RESULTS AND DISCUSSION
A genetic-based identification system was used to study the
composition of “pink slime bacteria” in pink slime deposits
prior to instituting slime control programs. The samples
came from mills located in the US, China, Germany and the
Czech Republic. Detailed identification of the culturable
bacteria was done for samples obtained from three of the
mills. For the remaining samples, attempts were made to
isolate only pink-or-red-pigmented bacteria. Table 1 shows
the bacteria identified in the deposits from the various mills.
In the six mills studied, the main cause of pink slime
varied to include Flectobacillus sp, Runella sp, Meiothermus
ruber, Deionococcus geothermalis, and Serratia marcescens.
Flectobacillus sp. are pink-pigmented filamentous bacteria.
In this work we found them in three of the mills studied.
This study, coupled with our experience from many other
3, 4,
indicate that they are the main cause of pink
studies,
coloration in many “pink slimes” in modern paper machines.
In one mill, Flectobacillus sp. were found together with
Rhodovarius lipocyclicus which were red-pigmented but
short rods. Rhodovarius sp. have been found in other
12
places but no information about their occurrence in the
paper mill environment could be located.
In one of the mills, the cause of the pink slime was found
to be Runella sp. These are filamentous bacteria and they
13
have been isolated in a wastewater treatment plant and
14
water bodies, but neither information about their occurrence in paper mills nor their association with “pink slime”
in paper mills has, to date, been published.
Meiothermus ruber and Deinococcus geothermalis were
identified as the cause of the pink slime in one of the mills
studied. In this mill, Meiothermus ruber was found to be the
dominant pink or red-pigmented bacteria. These organisms
are moderately thermophilic and they were isolated at 45
- 50˚C. The presence of Meiothermus sp. and Deionococcus
geothermalis in slime deposits and as the cause of red or pink
slime in paper machines has previously been reported.6
In the 1950s, Serratia sp. were commonly associated with
15
pink slime in paper mills, but many studies in recent times
have shown many different bacteria other than Serratia sp.
3, 4, 6
Interestingly, in one of the
as the cause of this problem.
mills in the current study, Serratia marcescens was the dominant pink- or red-pigmented bacteria found and the cause of
pink slime outbreak in that mill (Figures 1 and 2). Possible
reasons why Serratia sp. have become rare in recent times
3
have been explored and these included changes in machine
design and operation, paper making technology, furnish
types, biocides, and other additives.
Table1. Composition of “pink slime bacteria” from deposits from 6 different mills
Mill 1
(US)
Mill 2
(US)
Mill 3
(Germany)
Mill 4*
(Czech Republic)
Mill 5*
(China)
Mill 6*
(US)
Flectobacillus sp.
Runella sp
Flectobacillus sp
Meiothermus
ruber
Serratia
marcescens
Flectobacillus major
Ralstonia sp.
Sphingomonas sp
Caulobacter sp
Deionococcus
geothermalis
Janthinobacterium
sp.
Bacillus cereus
Aquaspirillum
Aquitalea sp.
Acinetobacter
anitratus
Acinetobacter
anitratus
Asticcacaulis
extrincus
Cytophaga sp
Pseudomonas
resinovorans
Burkholderia sp.
Chromobacterium
violaceum
Herbaspirillum sp
Klebsiella
pneumoniae
Sphingomonas sp.
Staphylococcus
epidermidis
Uncultured/
Asticcacaulis
Unidentified bacteria extrincus
Uncultured/
Unidentified bacteria
*Study was designed to isolate only pink-or red pigmented bacteria.
24
Rhodovarius
lipocyclicus
water treatment
feature
Figure 1. Serratia marcescens “red slime.”
Figure 2. Serratia marcescens culture.
Furthermore, a number of bacteria were isolated and the
16S rRNA gene sequenced but could not be “named” as
these bacteria either may not have been fully characterized,
or may not have been cultured in the laboratory before.
These were designated “uncultured/unidentified.” One interesting and unique thing about the use of sequence-based
identification in auditing is that the sequences of these
“uncultured/unidentified” bacteria can be stored in a searchable database and used in future searches. This database and
experience of how to control these bacteria provide a ready
tool in the event of pink slime outbreaks.
In conclusion, the identification system described in this
study was found to be quick, accurate, and less cumbersome
than the traditional methods. It allowed a large number
of isolates to be identified in a relatively short period of
time. The 16S rRNA gene sequences for the organisms are
stored in a database which can easily be searched when the
need arises. Additionally, the susceptibility of most of these
microbes to various control agents have been determined
(no data reported in the current work) and this information, among others, is used in making timely decisions about
appropriate control strategies for a particular situation. n
paper mill slimes. J. Ind. Microbiol. Biotechnol. 25:78-80.
4.Oppong, D., King, V.M., Bowen, J. 2003. Isolation and characterization of filamentous bacteria from paper mill slimes. Internat.
Biodeterior. & Biodegrad. 52:53-62.
LITERATURE CITED
1.
Ross, R.T., Hollis, C.G. 1976. Microbiological deterioration of pulpwood, paper and paint. In: Miller, B.M., Litsky, W. (Eds.), Industrial
Microbiology. McGraw-Hill, New York, NY, pp. 309-354.
2.Oppong, D., Bryant, S.D., Rangarajan, R., Steele, S. 2006.
Application of molecular techniques to identify bacteria isolated
from the leather industry. ALCA 101:140-145
3.Oppong, D., King, V.M., Zhou, X., Bowen J. 2000. Cultural and
biochemical diversity of pink-pigmented bacteria isolated from
5.Desjardins, E., Beaulieu, C. 2003. Identification of bacteria contaminating pulp and a paper machine in a Canadian paper mill. J.
Ind. Microbiol. Biotechnol. 30:141-145.
6.Kolari, M., Nuutinen, J., Rainey, FA., Salkinoja-Salonen, T., M.S.
2003 Colored moderately thermophilic bacteria in paper-machine
biofilms. J. Ind Microbiol. Biotehcnol. 30:225-238.
7.Suihko, M. L., Sinkko, H., Partanen, L., Mattila-Sandholm, T.,
Salkinoja-Salonen, M., Raaska, L. 2004. Description of heterotrophic bacteria occurring in paper mills and paper boards. J. Appl.
Microbiol. 97:1228-1235.
8.Mullis, K.B., Faloona, F.A, 1987. Specific synthesis of DNA in vitro
via a polymerase chain reaction. Methods Enzymol. 155:335-350.
9.Woese, C. R. 1987. Bacterial Evolution. Microbiol. Rev. 51:221-271.
10.Fox, G. E., Pechman, K. R., Woese, C. R. 1977. Comparative cataloging of 16S Ribosomal Ribonucleic Acid: Molecular approach to
Procaryotic systematics. Int. J. Syst. Bacteriol. 27:44-57.
11.Tracy, T.E., Mulachy, L.S. 1991. A simple method for direct automated sequencing of PCR fragments. Biotechniques 11:68-75
12.Kämpfer P, Busse HJ, Rosséllo-Mora R, Kjellin E, Falsen, E (2004).
Rhodovarius lipocyclicus gen. nov. sp. nov., a new genus of the alpha1 subclass of the Proteobacteria. Syst. Appl. Microbiol. 27:511-516.
13.Lu, S., Lee, J. R., Ryu, S. H., Chung, B. S., Choe, W-S., Jeon, C. O.
2007. Runella defluvii sp. nov., isolated from a domestic wastewater
treatment plant. Int J. Syst. Evol. Microbiol. 57:2600-2603.
14.Larkin, J. M., Williams, P. M. 1978. Runella slithyformis gen. nov., sp.
nov., a curved non-flexible bacterium. . Int J. Syst. Evol. Microbiol.
28:32-36.
15.Sanborn, J.R. 1951. Relation of red slimes to the general paper mill
slime control. TAPPI 34:490-493
David Oppong is Senior Biotechnology Research Scientist, and
Tod Stoner is Product Specialist - Deposit Control at Buckman.
For further information, please contact David Oppong: d_oppong@
buckman.com.
25
feature
reliability
maintenance - lubrication
Keep it Running Smooth
To succeed in today’s fiercely
competitive marketplace, pulp
and paper manufacturers
positively, absolutely, require
maximum equipment availability
and productivity from their
machinery, and a disciplined
lubrication management program
can make this happen.
By Tom Schiff
W
ing grades of paper or containerboard, maintaining a
THE IMPORTANCE OF A LUBRICATION
MANAGEMENT PROGRAM
safe work place, complying with applicable laws and
Most people believe just maintaining or adding lubricant
hether your mill is producing pulp, printing and writ-
26
producing profitable products with maximum quality are
to the rotating equipment provides effective lubrication.
all sound objectives for a world-class company. But, what
However, by not implementing lubrication program man-
does it take to accomplish these objectives? To be success-
agement, the opportunity to optimize equipment reliability
ful, manufacturers like yourself positively, absolutely, require
and maximize the return on your investment may be lost.
maximum equipment availability and productivity of your
Disciplined lubrication management is the foundation of a
paper machines and auxiliary equipment. To make that hap-
world-class lubrication program. The following chart illus-
pen you need a disciplined, world-class lubrication program.
trates the difference made in a plant’s total cost of owner-
This can be achieved by establishing some guiding principles
ship once you’ve taken that step.
that include:
Remember that implementing a disciplined lubrication
1.Setting the importance of a lubrication management
program.
management program comprises only one part of an overall
2.Defining the lubrication management program goals, and...
tive/predictive maintenance activities combined with good
3.Implementing the tools required to achieve the lubrication management program goals.
maintenance planning, scheduling, and execution are also
equipment reliability improvement program. Sound preven-
key to delivering maintenance improvements.
reliability maintenance - lubrication
feature
LUBRICATION MANAGEMENT
PROGRAM GOALS
To properly define the goals of your
maintenance managers. Many com-
lubrication management program,
panies look at lubrication on a price
use the following list. Choose those
basis and strive for methods to mini-
goals that will best meet your com-
mize that cost. Unfortunately, when
pany’s needs:
this happens, you may run the risk of
• Reduce lubricant related failures
forfeiting the true payback that can
lubrication needs to be a priority for
result from optimizing your lubrica-
• Use the fewest correct lubricants
tion program — improved equipment
and minimize waste
reliability AND decreased overall
• Apply the lubricant in the correct
maintenance costs. Be sure to nomi-
manner, at the proper time and in
nate a program champion — someone
the correct amounts
• Integrate the plant’s preventive
and predictive maintenance goals
into the lubrication program
• Continually investigate and imple-
Leadership. First and foremost,
who will assume the responsibility,
Most people mistakenly believe
just maintaining or adding lubricant
to the rotating equipment
provides effective lubrication.
ment methods to improve and
achieve the above goals
accountability and control for the
program. Plan for continual improvement and measure your progress on a
regular basis.
A good program requires dedica-
tion, skill and accountability. The discipline to “stick with it”
Once you’ve defined the goals of your lubrication man-
comes from strong leadership.
agement program, next you need to be sure you have the
Standard Operating Procedures (SOPs). Like other dis-
proper tools that will enable you to achieve these goals.
ciplines (operating or repairing machinery), SOPs can help
BASIC TOOLS REQUIRED FOR AN EFFECTIVE
PROGRAM
guarantee repeatability and quality work. Also, SOPs assist in
No single program works for everyone. There are many dif-
municate equipment condition.
ferent methods to achieve the goals of your lubrication man-
Teamwork and Communication. A world-class lubrica-
agement program. No matter what method you implement,
tion program must have a team that works and communi-
to ensure success, you should use the following tools.
cates with all members of the manufacturing group opera-
the training of lubricators and enable you to track and com-
Description
Before
After
Annual Lubrication Costs including Labor, Lubricant Costs and Supply Costs
$1,055,000
$845,000
Total Annual Maintenance Budget
$24,000,000
$22,000,000
Percent Annual Lubrication Costs vs. Total Maintenance Budget
4.4%
3.80%
Lost Annual Availability Due to Scheduled and Unscheduled Maintenance
6%
2%
Estimated Annual Profit Lost Due to Lost Equipment Reliability
$3,500,000
$1,200,000
Annual Maintenance Department Overtime
22%
14%
Annual Number of Equipment Failures Due to Poor Lubrication
18
2
Annual Volume of Lubricant Consumed (gallons)
62,000
15,000
Note: Table shows example numbers for demonstration purpose only.
27
reliability maintenance - lubrication
tions, maintenance,
science of lubrication
purchasing, planning
audits can become very
and engineering. The
involved, however, and
team champion is key
deserves a paper of its
is maintaining the com-
own.
munication and keep-
CONCLUSION
ing the team focused.
Safety, compliance,
Lubrication
and maximum qual-
Scheduling, Planning,
ity manufacturing are
and Tracking Manage-
sound objectives for a
ment Systems.
world-class company. A
To handle the quantity
disciplined lubrication
of data encountered
management program
(even for a small plant),
is what’s needed to
an effective computerized system should be
To continually improve, both program leader and lubricators
must continually learn best lubrication practices, as well
as learn new techniques in their specific discipline.
employed. Without
the aid of computer-
important equipment trends may be missed and/or documentation of the lubrication program may be lacking.
Training. To continually improve, both program leader
and lubricators must continually learn best lubrication
practices, as well as learn new techniques in their specific
discipline.
Metrics. Knowing the past performance and understanding the effects of program efforts enable you to make and
evaluate lubrication program -related decisions. The following metrics are useful when tracking your program’s progress
(other metrics not listed below may also prove useful).
• Total maintenance costs and percent spent on lubrication
• Percent of equipment scheduled and unscheduled
downtime
• Number of lubricant related failures
• Percent of maintenance overtime labor
• Lubricant consumption
• Safety Incidents
Audits. In order to improve, you need to validate or
audit your lubrication program. Whether performed internally or by a third party, the effort to benchmark and
evaluate your lubrication program against other “best in
class” operations will supply tremendous dividends. The
J A N U A R Y / F E B R U A R Y 2 0 1 4 tives. And, when you
set goals that put in
place the tools you
ized data management,
28
achieve these objec-
PaperAge
need to succeed, you are well on your way to establishing a
world-class lubrication program. n
Tom Schiff is Americas Field Engineering Manager for Exxon Mobil
Corporation. He has nearly 20 years of experience with ExxonMobil
and for 8 years has held the positions of Reliability Engineer and
Maintenance Superintendent for a prominent paper producer. For
further information about lubrication management, please visit: www.
mobilindustrial.com/ind/english/contactus.aspx.
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29
recycling matters
Continuous Commitment to Paper
Recovery for Recycling
Paper recovery has fostered a dynamic marketplace that allows recovered fiber
to find its highest-value use, which helps to encourage even more recycling.
By Donna Harman, President and CEO, American Forest & Paper Association
tive and cost-effective programs and
Recovering paper and paper-based
partnerships. The program generates
products for recycling has long been a
interest in developing new recycling
priority for our industry and an effort
programs; provides a resource to those
in which AF&PA members continue
looking to start or improve paper
to be proven leaders. Since 1990,
recovery programs; and supports the
when we first set a nationwide paper
industry’s on-going effort to increase
recovery goal, the U.S. recovery rate
recovery and maintain the quality of
has nearly doubled, topping 65 perrecyclable paper.
cent in 2012. According to the U.S.
Now in its ninth year, the AF&PA
Environmental Protection Agency, in
Recycling awards program has been
2011, only 27.6 percent of glass, 20.7
The
paper
recycling
industry
collects,
sorts
redesigned and continues to provide
percent of aluminum and 8.3 percent
and processes recovered paper into new
great visibility and reward those
of plastics were recovered from
paper and paper-based packaging products
engaged in successful paper recycling
municipal solid waste streams.
that were valued at $8.4 billion in 2012.
efforts.
Recovering paper products extends
In
each
category
—
school,
business and community —there
the fiber supply, which allows our industry to reuse its products
are now four chances to win. Programs will no longer be judged
to make new ones. It also saves an average of 3.3 cubic yards of
for their all-over performance, but on specific characteristics,
landfill space for each ton of paper recycled.
namely: volume – the total amount of paper and paperboard
AF&PA member companies have taken efforts to develop
collected; creativity – unique and innovative ways that have
and nurture a voluntary, market-driven system that fosters
been used to market the program, raise awareness and generate
consistently high rates of paper recovery. Our sustainability
interest; participation – unique and innovative ways successinitiative — Better Practices, Better Planet 2020 — includes a
ful programs increased participation and tonnage collected;
goal to exceed 70 percent recovery of all paper used in the U.S.
and partnerships – innovative partnerships with communities,
by the year 2020. Our members continually take strides
businesses and/or non-profit organizations used to promote
to improve the recovery of paper and paper-based packaging.
increased recovery.
The paper recycling industry collects, sorts and processes
This structure will allow for a greater focus on elements
recovered paper into new paper and paper-based packaging
that drive improved paper recovery program performance and
products that were valued at $8.4 billion in 2012. And the
increase recovery overall. It will also allow us to expand our
value of U.S. recovered paper exports totaled $3.5 billion in
reach and provide opportunities for more parties to engage and
2012. All in all, paper recovery has fostered a dynamic marketenter the program.
place that allows recovered fiber to find its highest-value use,
Descriptions of the awards, entry criteria and entry forms are
which helps to encourage even more recycling.
all available on paperrecycles.org. The deadline for all entries is
But paper recovery for recycling is a collective effort.
March 7, 2014.
Ultimately, it is possible and successful thanks to the commit Our industry has a proud tradition of achievement in paper
ment of millions of Americans who make the effort to recycle
recovery for recycling, and we are looking forward to recogat home, work and school every day.
nizing the invaluable involvement of businesses, schools and
We recognize excellence in paper recovery for recycling
communities in making paper recycling a success. Paper offers
through our annual AF&PA Recycling Awards program.
a recyclable product made from a renewable resource, which
First launched in 2006, the AF&PA Recycling Awards
is one of many strong points that makes paper the choice that
recognize and highlight businesses, schools and communities
consumers can trust and be proud to use. n
that increase paper recovery through educational, innova30
Experience the Paper
Industry’s Premier Event
co-hosted by
HELD AT THE NEW YORK PALACE IN MIDTOWN NYC
Industry Leadership Panel featuring:
John Williams President & CEO of Domtar
Dante Parrini Chairman & CEO of Glatfelter
Jack Sanders President & CEO of Sonoco
John Rooney President & CEO of Evergreen Packaging
David McGehee President of MacPapers
Paper2014 Luncheon keynote speaker:
Alex Sheen Founder of Because I Said I Would
Early bird registration closes February 28.
Register today at Paper2014.com
Committed to moving our
customers’ performance
forward – every day
Valmet Corporation is now an independent, listed company that was reborn through the demerger of the pulp, paper and
power businesses from Metso Group in December 2013. We develop and supply competitive services and technologies for
the pulp, paper and energy industries.
Valmet’s services cover everything from maintenance outsourcing to mill and plant improvements and spare parts. Our
strong technology offering includes entire pulp mills, tissue, board and paper production lines, as well as power plants for
bio-energy production. Valmet and Metso will continue to work closely together to offer winning automation solutions.
Our 11,000 professionals around the world work close to our customers and are committed to moving our customers’
performance forward – every day.
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dryer section performance

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