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Edito The Magazine dedicated to the Pulp, Paper and Tissue Industry in the Middle East

N° 13-14 Autumn/Winter 2011 Head Office ENP SA info@groupenp.com 36, rue Stanislas Julien - 45000 Orléans France Tél. +33 238 42 29 00 Publisher STÉPHANE RICHARD stephane.richard@groupenp.com Regional Office United Arab Emirates Burjuman Tower 18th Floor, P.O. Box : 121828 Dubai, United Arab Emirates Tel: +971 4 50 96 712 Fax: +971 4 50 96 797 Correspondants Lebanon RIMA DIB rima.dib@groupenp.com Egypt YASSER ZAKARIA sales@yzgroup.org Syria AHMED AL SLEEBA ahmed.sleeba@groupenp.com Jordan RAMI HOURANI rami.hourani@groupenp.com Advertising Middle East rima.dib@groupenp.com Tel: +961 32 24 953 International Advertising STÉPHANE RICHARD stephane.richard@groupenp.com FRANÇOIS HÉNIN francois.henin@groupenp.com Tel: +33 238 42 29 00 Fax: +33 238 42 29 10 Graphic Designers ELHAM EL MASRY GHALI SIMON & PARTNERS Subscription MATHILDE SEVESTRE mathilde.sevestre@groupenp.com

Goodbye 2011 ! Welcome 2012 ? e will not miss this opportunity to wish all our readers, in the Middle East and beyond, a happy New Year, full of peace and happiness. We extend our best wishes to the whole paper industry worldwide.

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2011 has been a crucial year for the Middle East region. Some huge political changes have been initiated. However, in various countries, the system needs to be reinvented in a way the People will accept. It now has its word to say, and knows how to claim it. Turmoil might persist for a while before a fragile equilibrium can be found. Because consumption is a key factor for the paper industry, let’s hope the region will rapidly find economic and social stability. In the rest of the world, the economic growth is also at stake, but for very different reasons. If spring will remain in our minds as the crucial season for the Arabic countries, winter has been a deadly time for Europe and its commercial partners. The interdependence of the financial markets is eventually putting pressure on every citizen. However, despite this gloomy environment, 2012 should still show a rise in paper products demand globally, especially paperboard, tissue and specialty papers. In order to face this increase, paper makers of the Middle East should adapt their production lines and start to invest, keeping in mind that the technical age of their mills is above 20 years old, twice older than in China. 2012 will be another challenging year.

Diffusion : 3.000 ex. Algeria, Bahrain, Egypt, Iran, Irak, Jordan, Kuwait, Lebanon, Morocco, Oman, Qatar, Saudi Arabia, Syria, Tunisia, United Arab Emirates, Yemen

www.groupenp.com Official Media Partner

Stéphane Richard stephane.richard@groupenp.com papermiddleast 3


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Magazine PAPER MIDDLEAST ENP 36, rue Stanislas Julien F-45000 Orléans – FRANCE Tel : ++33 238 42 29 00 / Fax : ++33 238 42 29 10 / mathilde.sevestre@groupenp.com If you have any questions or comments, please contact us at: info@groupenp.com

A DV E RT I S E R S I N D E X ABK ................................................................15 Algas..........................................................18, 48 Arab Paper Academy........................................59 BTG ..........................................................25, 40

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Fibretec ..........................................................20 Paper Middle East 2012....................................21 Paper One Show 2012 ......................................39 Syropaper ........................................................35


Contents

4

Newsletter subscription

Paper Arabia 2011 10

News 6

6

Islamic Paper Manufacturing will finalize his rebuild Metso introduces a solution for increasing capacity in the world’s wastewater treatment plants

UAE paper consumption is among the highest in the world !

Paper Middle East Cairo 16

Clariant presents value-creating innovations at Paperex India 2011

8

Cascades rethinks protective packaging once again

9

International Paper completes acquisition of majority Stake in Andhra Pradesh Paper mills

22

Report

Paper-ME 2011 is your gateway to the Middle Eastern and African market

Interview

7

Report

Laila Ghanem, CEO of SIMO

Mrs Layla Ghanem, a top lady in the Arabic Paper Industry

Technology 26

New Dryer fabrics based on Smart Surface TechnologyTM from Asten Johnson

28

Measurement and control of optical brighteners using inline sensor technology from BTG

Products and solutions

9

Paper & Plastics Recycling Conference Middle East announced

36

Safety and efficiency through total tail control from Metso

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News

EGYPT

Islamic Paper Manufacturing will finalize his rebuild Islamic Paper Manufacturing will soon finalize a rebuild of its two machines, PMs 1 and 2, at its Quesna mill in Menofeya, northern Egypt. The firm is adding a new dryer to PM 1 to increase the productivity of the machine. It can currently manufacture some 30,000 tonnes/year of recycled fluting and testliner but the capacity should increase to 50,000 tonnes/year after rebuild, scheduled for completion in September. The unit will also be able to produce white-top testliner following the revamp.

WORLD

Metso introduces a solution for increasing capacity in the world’s wastewater treatment plants Metso has developed an online measurement technology with which municipal and industrial wastewater plants are able to improve their performance and reduce the amount of chemicals used in sludge drying process by even up to one third. The new Metso Low Solids Measurement is the first online measurement technology for municipal and industrial wastewater treatment plants that enables measurement of a media with very

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low solids contents in difficult applications like centrifuge centrate. The technology also offers significant savings per centrifuge in polymer and centrifuge usage. Until now, there has not been any online measurement technology available that would enable reliable measurement of a media with very low solids contents in this measurement position. “The new technology developed by Metso offers the world’s water treatment plants an opportunity to improve their performance and thus gain major cost savings. A large North American wastewater treatment plant has calculated that it saves even up to 30% in its annual USD 2.5 million chemical costs. In addition, a municipal plant in Finland using Metso LS™ estimates that they will achieve annually EUR 15,000 savings in polymer and centrifuge usage only by keeping reject water total suspended solids lower that 1000mg/l”, says Timo Rantala, Product Manager, Metso’s Automation business line. The Metso Low Solids Measurement system is based on LED and laser technology. It dearates, filters, and measures the process solids along with possessing self-cleaning capabilities to keep the measurement optics clean for continued accurate measurement. It complements Metso’s measurement product portfolio to the wastewater processes. Earlier Metso has launched Metso TS™, total solid measurement to the waste water treatment processes. Metso TS is based on microwave technology. Key benefits With Metso LS measurement it is possible to control polymer usage and thus improve throughput and function of the centrifuge. A hi-


News

gher solids content of concentrated sludge results in higher thermal energy in the subsequent incineration process, or alternatively reduces transportation costs when shipping to a landfill. Furthermore, Metso LS reduces conventional sampling and laboratory work due to its reliable and accurate operation. The small investment in an online solids measurement system gives significant operational savings and correspondingly a very short payback time. Typical applications Metso LS is specially developed for municipal or industrial wastewater treatment processes to measure low solids in difficult applications. Typical such application is centrifuge centrate water solids. The device gives accurate information about centrate water quality, enabling the process to be controlled in the most cost-efficient way. A too high solids rate in centrate water would cause the excess solids to be repeatedly treated and centrifuged. Reliable information about the centrate water quality is very important for choosing the right polymer and to determine the right polymer dosage. Operation principle in a nutshell The Metso LS device can be connected online to the process and is able to measure continuous sample flow through the system by utilizing an integrated centrifugal pump. The device has two light sources, LED and laser, that measure absorption, scattering and depolarization of these sources as they pass through the flowing media. The measurement cell has an extremely strong sapphire glass with high optical properties. The cell and sample lines are automatically cleaned at given intervals. Metso LS continuously measures the suspended solids content within the range of zero to 5000 mg/l and also the entrained air index, which indicates overdosing of polymer. The Metso LS measurement system dearates, filters and measures the process solids along with possessing self-cleaning capabilities to keep the measurement optics clean. Global potential “In the first phase, the new technology will most probably interest especially large wastewater plants in Western Europe and North America, where the level of automation is already high. It is these plants that often have major capacity issues and are under pressure to save costs. Interest in these kinds of solutions is growing in Asia, too,” Rantala comments.

In the past five years, Metso has strengthened its role as an expert in wastewater treatment, and is now the market leader in microwave technology measurements used in treatment processes.

INDIA

Clariant presents value-creating innovations at Paperex India 2011 Clariant shines the spotlight on the performance and cost-optimization benefits of its colorants, optical brightening agents and chemicals for paper at Paperex in New Delhi, India from December 10 - 13, 2011. The specialty chemicals expert will present its latest cost-effective solutions designed to enhance papermakers' products and processes. Highlights at Clariant's Booth in Hall 7G - 7723 will include: New optical brightening agent (OBA) Leucophor® XL: the novel tinted OBA for surface application gives a truer white and less red shade, providing high-white grades of paper with less OBA and shading dyes/pigments at a lower cost. Award-winning stickie-reducing innovation Cartaspers® PSM: minimizes stickies and pitch on sieves and felts by passivation and thereby increases machine running time. At the same time, exposure to volatile organic compounds (VOC) for both factory staff and the environment is reduced. In recognition of this achievement, the US Environmental Protection Agency (EPA) awarded the Pollution Prevention Recognition Award to Cartaspers PSM.

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News

WORLD New Deposit Control range addition Cartaspers® SCH: developed specifically by Clariant to improve machine cleanliness and runnability when wastepaper is used as a raw material in the papermaking process. Cartaspers SCH works through a mechanism of passivation, combining with pressure sensitive adhesives, latex binders, pitch and all other potential stickie contaminants, to give them a hard protective shell, which prevents agglomeration and reduces the tendency of stickies to foul machine clothing. The increased softening point of the passivated stickies helps prevent "picking" in the drying section and the transfer of contaminant to the hot cylinders is significantly reduced.

WORLD

Cascades rethinks protective packaging once again The Industrial Packaging Sector of Cascades Specialty Products Group rethinks protective packaging once again with Flexicomb™. This brand new flexible protective packaging is both economical and eco-designed. Made from 100% recycled materials, Flexicomb is the alternative when it comes to economical and environmentallyfriendly flexible packaging providing product protection. Easily adapted to irregular shapes, this new packaging eliminates the risk of damage during shipping and handling. Flexicomb also employs FiberSmart™ technology, which is available with a cohesive coating option. Also, in collaboration with Trans Industrial Packaging Ltd, Cascades is proud to offer ThermaFresh™. This new industrial packaging innovation is an ingenious eco-designed option to replace traditional fresh fish packing containers. It is made of water-resistant corrugated paperboard, metalized paper film and paperboard honeycomb cells. The advantages of ThermaFresh are numerous and include a reduction in shipping and product damage-related costs. By rethinking protective packaging, Cascades provide the industry with a high-performance, cost-effective solution for the packaging and distribution of fresh food.

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Metso’s new Fiber to Print solution ensures optimum printing results Metso now offers combined process performance control and product quality management coordinated across the whole production process. Metso’s new Fiber to Print solution links a complete suite of process control, quality management and environmental solutions that collectively optimize the whole chain from pulp production to end-product. Metso combines the analyzers and controls to stabilize the process, QCS quality control, automated laboratories, as well as advanced controls for end-product management and to optimize productivity. To complement the Fiber to Print solution Metso introduces new online surface & structural measurements and camera based web inspection systems. Fiber to Print is based on data collection and management across the whole process. All the collected data is time-syncronized into one quality report. For example, synchronizing data from Metso Paper Lab automated paper quality laboratory and on-line quality sensors, all the way back to analyzers in pulp preparation, provides a full picture of the quality building process for further optimization. Customized solutions over the entire production line Significant reduction in chemical use is achieved with mill wide brightness optimization, which coordinates pulp bleaching to final paper brightness. Printing house reclamations can be significantly reduced by applying new developments in online measuring of paper structural and surface properties. Camera based web inspection and online scanning by optical and imaging based technologies coordinated with upstream wet-end analyzers now provide new and improved tools to predict paper or board print quality earlier than ever. ‘’Today’s papermaker’s recognize that a major part of paper,and board quality is built before the head-


News

box. By the time fiber furnish gets to the machine, it is too late to correct the mistakes done for example in pulping. That is why Metso offers combined process performance control and product quality management coordinated across the whole production process,’’ says Jukka Sorsa, Director, Pulp&Paper Applications, automation business line, Metso.

INDIA

International Paper completes acquisition of Majority Stake in Andhra Pradesh Paper mills International Paper (NYSE: IP) today announced that it has completed the acquisition of a 75 percent stake in Andhra Pradesh Paper Mills (APPM). International Paper purchased 53.5 percent of the APPM shares from Mr. L.N. Bangur and related family members and affiliates for approximately US$226 million in cash. These sellers have also entered into a covenant not to compete, for which they received a cash payment of US$57 million. In addition, International Paper acquired an additional 21.5 percent of APPM shares in a public tender offer completed on October 8, 2011, for approximately US$105 million in cash. Paul Brown, president, IP India, will become executive chairman of the APPM Board of Directors, effective today. "As we complete this phase of the process and move into majority ownership, International Paper is wellpositioned to help serve a rapidly growing Indian market," said John Faraci, International Paper Chairman and Chief Executive Officer. "We look forward to building on Andhra Paper's tradition of excellence while introducing the global best practices that make International Paper an industry leader. We are delighted to welcome these new employees to International Paper." APPM is one of the leading integrated paper manufacturers in India, and operates two mills with a combined annual capacity of 250,000 tonnes of uncoated freesheet paper. The existing management team and 2,500 employees of APPM will continue to operate the business, supplemented by additional International Paper leadership and professional and technical resources.

WORLD

Paper & Plastics Recycling Conference Middle East announced Media Fusion, the publisher of Waste and Recycling Middle East and Clean Middle East announce their cooperation with US-based Recycling Today Media Group to offer a conference on paper and plastics recycling. The event is being introduced on a joint venture basis in the region. The Recycling Today Media Group have extended their very successful Paper Recycling Conference with the addition of a new geographic event, Paper & Plastics Recycling Conference – Middle East. The event will be held 27-28 February 2012 at the JW Marriott hotel in Dubai, UAE. “We’re thrilled to be cooperating with the team at Waste & Recycling Middle East to introduce this new event,” commented Jim Keefe, Group Publisher of the Recycling Today Media Group. “By offering a high quality business conference for the rapidly developing Middle Eastern market we hope to provide both valuable insight into the local and global market and also develop commercial opportunities for the industry,” continued Keefe. The event will combine market driven sessions examining commodity markets for recovered paper and plastics in a global context, insights from local policy makers on regional waste and recycling management development and case studies of how the industry is being developed from local recyclers. “As we explored the possibility to develop such an event for our local market we wanted to partner with global market leader that offered a proven track record. Partnering with Recycling Today has allowed us to do that,” said Dr. Kayyum Ali Bohra, Head of Operations for Waste & Recycling Middle East. “Building upon the success of Paper Recycling Conference – USA and Paper Recycling Conference – Europe we are confident we can offer recyclers in the Middle East a world class event right in their back yard,” added Bohra.

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Paper Arabia 2011

Report

UAE paper consumption is among the highest in the world! UAE growth in packaging paper and board industry is between 6-7% and Paper Arabia 2011 opens with clear trend of Chinese producers increasing their exports to the Middle East.

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he 4th Paper Arabia show 2011, the biggest paper show in the MENA region and the first-of-its-kind industry expo, was inaugurated by HE Abdul Rahman Saif Al Ghurair, Chairman, Dubai Chamber of Commerce and Industry, on Sunday 18 September, 2011 at the Dubai International Exhibition and Convention Centre, the event continued until September 20. Al Ghurair said that the paper industry is still evolving in the UAE and that it serves the entire region and Africa.

The UAE consumed 3.5 million tons of paper in 2010, against 18 million tons in the entire Middle East region and 450 million tons globally, according to International Pulp and Paper Association. A4 paper led the demand for paper, and the overall growth in paper consumption is between 5 and 6 percent where 12 paper mills operates in the country as revealed by the Organizers. The Indonesian Pulp and Paper Association, one of the biggest associations in the world specializing in paper, showed that the per capita annual consumption of paper in the UAE is 10 papermiddleast

200 kg, against the global average consumption of 60 kg. This is a significant figure for the UAE with a small population, when contrasted with a country like India where the per capita consumption is mere 9 kg. UAE’s consumption is on par with Italy and Spain.

At the conclusion of Paper Arabia 2011, key players approved that the digital boom in the Middle East is not largely affecting the printing of paper as seen from the fact that UAE is among the highest consumers of paper in the world despite the increase penetration of electronic pads in the country Figures given; it is estimated that 110 million pads were produced in 2010 globally, that reduced the consumption of paper by 1.1 million tons. Each pad displaced 10 kg of paper including newsprint, photocopy and office paper but it has added 3 kg for packaging each item. Despite digital media growth, the Middle East’s annual consumption of paper will increase to 29 million tons by 2020 according to international industry statistics released on the sidelines of Paper Arabia exhibition.


recent unrest in some countries, the traders have grown more cautious and have adopted a wait and watch approach. They have to buy the paper in cash and they don’t want to take risks. So in countries which are going through rough political climate, the business is on hold but that doesn’t mean that the business isn’t growing in the Middle East and growth in countries like Saudi Arabia and Egypt is tremendous. When asked about effect of digital media on the printing industry, Kilam said: “We heard ten years ago that school books would vanish and it didn’t happen. Similarly, we will always hear the same for news print, but it seems this is a long way to go, which will keep the consumption of paper on the rise”.

Suresh Kilam, Vice Chairman of Indonesian Pulp and Paper Association said: “Chinese paper and pulp industry will reach 168 million tons in 2020, 22 million of which will be exported outside Chinese markets, with the Middle East getting the bulk of these exports in the absence of antidumping policies. Chinese production was 92 tons in 2010 compared with 32 tons in 2001.” He added that the global consumption of paper would reach 495 million tons in 2020.

Satish Khanna, General Manager, Al Fajer Information and Services, organizers of the show, said: “Paper Arabia 2011, the first-of-its-kind industry expo attracted over 6120 trade visitors. Big names such as APP- the company’s sponsor of the 4th Paper Arabia show 2011-, Abu Dhabi National Mill (ADNPM), Orient Links and others participated in full force in Paper Arabia 2011 and introduced new technologies, products and concepts such as new textured tissue by ADNPM which received lot of attention by visitors. This year many companies offered environmentally friendly products based on agricultural or post consumer wastes. Paper Arabia has grown to become a must attend event opening doors to paper industry in the Middle East and beyond”.

North American paper market is shrinking at 1.8 percent yearly, and same applies to Western Europe market. Talking about the importance of using latest technologies in saving production costs, Kilam confirmed that China is adopting new technologies that are reducing the cost by almost half. As per the tissue industry in the region, Kilam said that it was growing rapidly: “there were 4 major machines in 2010, against only one in 2000”. Being also the Executive Director at APP (Asia Pulp & Paper one of the world’s leading pulp and paper companies and the largest vertically integrated pulp and paper producer in Asia, excluding Japan) Kilam believes that with the

Mr Khanna papermiddleast 11


“This specialized show is to highlight to key international players the importance of being a part of the region’s booming paper industry. The paper, tissue and converting industries displayed the latest technologies at the three day show. This is the only such show in the Middle East that is really making rapid strides year after year…” as Khanna explained.

gin pulp. The mill houses a pulp store, machine house, stock preparation facilities, tissue machines, de-inking plant, warehouse and offices.” *Berger is a globally recognized authority in the Paper industry. He is also an inventor of a production innovation which was awarded a global patent.

The de-inking plant is among the most sophisticated in the region, which converts waste paper into commercial tissue fiber of high quality. Berger added that the total capacity of the de-inking plant is 30,000 tons. Recycled paper usage within the Paper Mill production process helps save the environment by reducing pure pulp usage.

He added: “Paper industry is developing all over the world, especially in the Middle East. We have high hopes for this industry in Dubai and the potential is really huge. Paper Arabia 2011 is dedicated to the development of the paper, printing and packaging industry in the GCC and reflects our efforts to highlight key regional industry segments”. Elite players from the paper, tissue and converting industry participated in Paper Arabia 2011 because they believe it can offer them huge opportunities. With more than 150 exhibitors from 30 countries from across the world, and being a key platform for traders and industry players to interact, the show’s participants included leading global names from the UAE, Italy, Jordan, India, China, Netherlands USA and UK amongst others. The Abu Dhabi National Paper Mill (ADNPM) a subsidiary of Abu Dhabi National Industrial Projects Co. (ADNIP) manufacturer of jumbo tissue rolls said that unlike writing paper, tissue has a major growth in the world; in the UAE, tissue market is growing by 5 to 8 percent. Helmet *Berger, newly appointed General Manager at ADNPM, said: “ADNPM, spread over an area of 60,000 sq m, uses state-of-the-art Crescent Former tissue machines to produce world-class paper from the highest grade vir12 papermiddleast

ADNPM has also installed a water treatment plant whereby 40%-60% of the waste water is treated and re-used, rather than being dumped into sewerage. This helps the Paper Mill in not only reducing energy consumption but also in being environmentally friendly as confirmed by Berger. Satish Khanna, commented by saying: “We are pleased to have ADNPM to participate in Paper Arabia show. In a short span of time, ADNPM has carved a niche for itself as a leading regional manufacturer, with a reputation for being a state-of-the-art independent producer of tissue paper”. Sunil Bakht, Orient Links Co. Chairman said that he was happy with the quality of visitors; “The visitors are much focused this year, we met with many visitors for environmentally products and the demand is high and we are responding to it very efficiently, and we are aiming to become a carbon neutral country by next year” as he confirmed. Bakht added: “Regarding Paper Arabia and its


position as the leading paper show in the region, some are skeptical about the yearly frequency of this show. However, I believe that Paper Arabia is emerging as the leading paper trade exhibition in the region with its own character”. Orient Links showcased a wide range of products at the show and they have recently ventured in packaging market. The paper industry in the Middle East has been on the move and the value of the Middle East printing substrates is forecast to reach $5.0 billion in 2012, according to Pira International. Khanna confirmed that with the demand for tissue and household papers on the rise in the region, Chinese pavilion has grown by over 20 percent and that this year, the Chinese National Household Paper Industry Association along with 17 companies participated at the show. Youssef Amin Jaber, Sales and Marketing Manager, Saudi Paper Converting Paper said that the show was very good and they have had the opportunity to be closer to customers and partners. INPAP said that it added new range of specialty papers to its kitty, while Abros launched innovator, multifunction A4 paper. Intec Printing Solutions, a UK based company announced the appointment of Altech International FZE to sell its range of world leading heavy stock and specialist media partners in the Middle East region and in Africa. The paper industry has been registering spectacular growth with several production centers and paper converting businesses flourishing and the show placed special emphasis on hygiene and disposable products, in view of the surge in demand for various products like wet wipes, baby diapers and sanitary napkins. Paper Arabia 2011 brought together players from the paper, tissue and converting industries. This show offered opportunities to the manufacturers and suppliers of finished products, equipment, machinery, paper chemicals, services, supplies of paper, tissue and converting sector to tap the Middle East and North African markets. papermiddleast 13


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Paper Middle East Cairo

Report

PAPER-ME 2011 is your gateway to the Middle Eastern and African Markets From our correspondent in Egypt, Yasser Zakaria he three-day exhibition didn't only witness the gathering of the exhibitors but the visitors as well bringing together the leading manufacturers and distributors from all sectors under one roof to benefit from the Middle Eastern and African's unique and prosperous market first hand.

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to the event which was "Packing and Packaging Industry" which designed to give specific exhibition identity; the initiative attracted leading companies in the sector of Packing and Packaging. Really it was a brilliant and successful step

Exibitors summary The event had provided an opportunity for prominent international and local exhibitors to meet face to face with paper makers and professional leaders concerned in Paper industry in Egypt, Middle East and Africa. This vital and direct meeting was the gateway that enables the international and Egyptian exhibitors to penetrate new alternative markets in the region and the Black Continent. Among the most prominent achievements at this year edition are the trade missions coming from different countries that are decision makers highly sought after higher board and senior management members from all major sectors of the Paper Industry. The trade missions were invited by PAPERME2011 and were so keen on attending this event and had shown interest in visiting some of the Egyptian companies and factories and meeting with the numerous exhibitors who were participating in the event from all over the world which had ended by generating and closing up many business deals. PAPER-ME2011 hosted a new and vital sector 16 papermiddleast

NUMBER OF EXHIBITORS

114

INTERNATIONAL EXHIBITORS

60

EGYPTIAN EXHIBITORS

54

INTERNATIONAL COUNTRIES

20

TOTAL SIZE OF THE SHOW

4,900 SQM

Although the total number of exhibitors is less 10% than the last year's edition and accordingly the exhibition area is less with 12% , yet the sales leads and the purchase decisions that were made were more and more, which indicates the success of this edition due to the high traffic of the picky visitors and buyers who were so relevant to the exhibition sectors

Exhibitors Survey - 90% of exhibitors were successful in meeting their overall objective at the show - 88% of exhibitors stated that they met or surpassed their objectives in terms of sales and si-


gned deals made during the exhibition - 85% of exhibitors had met or surpassed their overall objectives in terms of establishing contacts for future sales - 89% of exhibitors were satisfied qualitatively and quantitatively with the visitors who had surpassed their expectations - 87% of exhibitors stated that their Return on Investment were met and surpassed their expectations

- 86% of exhibitors had expressed their interest in rebooking the next year with a bigger booth 12% of exhibitors had suggestions to better improve the show for the upcoming editions

Paper Middle East 2011 - Cairo papermiddleast 17


Reasons for Exhibiting

"We have to thank all the team working on this exhibition for the support we had during the days of the exhibition, you will see us next year in PAPERME2012" Algas GmbH – Germany

What Exhibitors Said "It is a great show, we met so many customers. The Middle East and Africa has been supporting our business, they are growing much faster bringing in more technology. All we see is a growth in part of this world. It is probably one of the best venues for introducing your products into this part of this world." Mr. Dan – Eridan International – Thiland

"This is my first time to participate in PAPER-ME Exhibition as the market is growing up and it is a good chance for us to get services for customers and offer and hopefully to sell them our products with best quality. It is a good exhibition because you meet customers face to face discussing many projects and business. I am happy to be here." IBS - Austria

"We are so glad to take part in PAPER-ME2011 Exhibition. We realize that Middle East is a fast-growing market by your successful exhibition. We would like to transfer this information to Chinese Paper Enterprises." China Pulp and Paper Magazines Publisher – China

"Egypt is considered to be a very big market that we are keen to be presented in, in order to keep our clients and to meet with new clients as well through PAPERME Exhibition" Saudi Paper Converting Co. – Saudi Arabia

Visitors summary NUMBER OF VISITORS

9366

NUMBER OF COUNTRIES

40

TOP COUNTRIES

GERMANY, FRANCE, CYPRUS, ITALY, TURKEY, AUSTRIA, ZAMBIA, CZECHREPUBLIC, UGANDA, NIGERIA, KENYA, INDIA, SYRIA, QATAR, LEBANON JORDAN, MOROCCO, SAUDI ARABIA AND MUCH MORE

- 87% of visitors were satisfied with the product range that met their interest and needs - 85% of visitors expected to do business with the exhibitors - 15% of visitors said that they will participate as exhibitors in PAPER-ME2012

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Thank you

" It was a great pleasure for us to stay on the Paper Middle East Show 2011. We would like to say thank you to all the visitors, customers and friends who visited our stand during the exhibition." ALGAS MICROFILTERS are today being used instead of or to supplement traditional water and effluent treatment methods in paper mills and industrial industries world-wide. Their compact design and flexibility of operation provides a better method of treatment helping mills world-wide meet the need to conserve raw materials, chemicals and save fresh water by treating process water, and thereby reducing pollution. ● Fibre recovery ● Re-use of water in place of fresh water ● Polishing water after existing savealls to enable re-use ● Recovering water & fibre from screw and belt presses ● Primary effluent treatment ● Polishing before Bio and after secondary Bio treatment before final discharge Röchling Leripa is your complete supplier offering top quality wear parts for the paper industry.

● Suction

Roll Sealing Systems ● Coating Rods and Beds Cones ● Doctor Blades ● Dewatering Elements and Components like ● Plastic covers from UHMW-PE ● Ceramic covers ● Stainless Steel Boxes ● Service Team and Maintenance ● Headbox Vanes ● Cleaner

During the past century the Paul Wegner company in Hagen (Germany) has successfully operated in the history of the papermaking industry. Our main products are: ●

Creping Blades

● Doctor

Blades

Coater Blades

● Special

knives

Integrated Solutions for the Paper Industry by M Consult GmbH The staff of M Consult GmbH rely on long-standing experience in the paper making fields. Projects are well-done by an integrated team of engineers, technicians and design engineers with profound expertise in pulp and paper production, process engineering, environmental technology, machine building and construction engineering, electrical engineering and instrumentation technology. Backed by modern CAD and communication technologies, project management is professional and efficient. Our experts elaborate efficient and profitable solution concepts in the areas of pa-

permaking, circuit water & effluent treatment, energy engineering, instrumentation technology and environmental protection. The range of our service missions includes engineering, project management & coordination, tender invitations, purchasing support, budgetary control and progress control, layouts and installation management - quite apart from plant commissioning and trainings of mill staff. In short – we provide customer relief. Villforth Siebtechnik GmbH is a family owned traditional supplier for the pulp and paper industry. We are located in Reutlingen, South Germanysince 1870. We are focussed on : ● ●

Forming fabrics ● Trouble shooting ● Wires for all dewatering purposes Roll covers (shrink sleeves) ● Wires for the stock preparation

Established in 1989, PMS (Papiermaschinen-Systemtechnik) GmbH specialized in nozzles,showering and edge trimming systems for the papermaking industry. When introducing the ruby nozzle technology PMS achieved an optimization of paper machine efficiencies worldwide. From this position PMS was early to recognize that joining forces with its customers in a long-term mutual and successful learning process is how typical problems in papermaking can be solved. With its worldwide activities, a team of today 13 highly qualified and motivated employees and a global sales network, PMS makes the difference by offering best service and best available product quality: e.g. ruby nozzles for high pressure pipes, ruby nozzles for edge trimming, edge trimming systems, pump systems for the supply of edge trimming systems and tail cutters, tail cutter modification kits, increased Paper Machine productivity, improvement of quality by optimized felt and wire conditioning. IKS KLINGELNBERG GROUP: A DECISION FOR QUALITY AND SERVICE The name IKS Klingelnberg stands for a global operating group of companies which manufactures a high variety of circular as well as straight knives for the Tissue Paper Industry. The products for the Tissue Paper Industry are produced in 3 German production sites and 2 Austrian sites. All plants are certified according to ISO 9001. Continuous research regarding the further development of materials and production processes as well as decades of experience have made IKS Klingelnberg a global player and one of the highest-skilled knife specialists. Product portfolio for the Tissue Paper Industry: Log Saw Blades, Lubrication System, Lubricant, Grinding Stones, Perforation and Anvil Knives, Packaging Knives, Slitters and Knives for the production of Handkerchiefs, Napkins and Towels. Additionally we offer Technical Seminars and Best Practices. IKS KLINGELNBERG – YOUR PARTNER FOR CUTTING SOLUTIONS!

If you need further informations please contact : www.algas.de - www.leripa.com - www.paul-wegner.com - www.mconsult.de - www.Villforth.com - www.rubynozzle.com - www.interknife.com


"Egypt is being a good and promising market for the Paper industry in the means of importing and exporting, playing a main role in the industry in the MENA Region. The show was great." India

"The exhibition was good mainly because of the variety of the business represented in the variety of exhibitors. I had a good time and I am trying really to expand my business activities with the Egyptian suppliers." Cyprus

International exhibitors who had participated in PAPER-ME2011 trust in the Egyptian market that can accommodate the new products and technology, which strongly help in attracting investors to Egypt after the revolution. We trust that this exhibition had achieved more benefits than it was expected for all sides, and the next one on 2012 will be more effective and even better. 


Interview

Laila Ghanem, CEO of SIMO

Mrs Layla Ghanem, a top lady in the Arabic Paper Industry From our correspondent in Egypt, Yasser Zakaria

he Arab paper industryhas an ancient history. Many companies and mills have gained a pioneer reputation in this sector through the years, led by a group of excellent and well qualified managers and experts. However, no lady had ever had the opportunity to play a leading role in any of the Arab mills, and be responsible for technical and managerial decisions. Until Eng. Layla Ghanem became the first woman to reach such a position when she became CEO of MIDDLE EAST PAPER (SIMO). Right after her graduation from faculty of engineering, she joined the paper industry. Very quickly, she developed her technical and managerial skills, the two pillars of her brilliant career. After she was just appointed at the head of SIMO,

T

22 papermiddleast

we had the chance to ask her a few questions. • First of all, could you tell us more about your professional background and why you chose to work in the paper industry When I obtained my diploma of engineer from Ain Shams University in 1974, with a specialization in electricity, I was assigned to the ministry of industry. Shortly after, in March 1975, I joined SIMO as my first work place.

• What have been the different steps of your career within SIMO? I started as a junior engineer; I was responsible


for all electrical works such as machines maintenance, cables and equipment, high and low pressures cables, etc. In two weeks I had a full understanding of the all electrical system of the production line and networks. This wouldn’t have been possible without the great cooperation I had from all the engineering staff who worked there at this time. They were professors and teachers for me. After that I became Head of the electricity department in SIMO, and was rapidly assigned as Director. Then I was promoted General Manager of electricity, equipment and workshops, before becoming Head of the engineering sector in 1996 till 15th May 2011. At that date I was proposed the position of Executive general manager and managing director in SIMO, which I proudly accepted.

• Normally most of people feel a lot of different feelings in their first day at work. What were those feelings on your first day, and did you have a clear ambition? Actually I remember that in my first day at work, I was very excited about it. After my meeting with the engineering manager I started my work directly in the mill to know everything about how it runs. I owe this enthusiasm to my professors and engineers at Ain Shams University. They always motivate their students to work hard, give them the required enthusiasm and ambition for success. My ambition was to leave my fingerprint in SIMO and never leave it. That’s why I refused all other job offers over the years. Doing so, my dreams came true.

• The paper industry in the Middle east is very successful, but women have a very limited technical role in it unlike the managerial one. You are today the first lady to handle such a leading position in the entire Arab region. That must have been a frightening responsibility.

ving my goals, and doing my work in the best way. From the very beginning at SIMO, I was determined to be successful, although I was the only female engineer at SIMO. Of course there were other female colleagues, but in administrative positions. I was lucky to have cooperative colleagues, be they engineers, technicians or workers. We were all hard-working people with mutual respect. • What were the difficulties you faced originally? Considering my lack of experience, some of my colleagues were dubious about my competences, and hardly accepted the fact that a female engineer at the beginning of her life career would supervise their work. But I was able to make all these feelings disappear by my simple way in dealing with them, without any ego from my side. I even made them feel that I wanted to learn from their experience, and want them to learn from my academic knowledge which I gained through my study in the university. And so, in time we all worked in a very cooperative feeling, and thank God for that. • Paper Company for Middle East (SIMO) is a very well known company in this industry, and has a great history. Could you please tell us more about it? Indeed SIMO is one of the well-known companies in this industry. I started operations in 1945 as a private company. In 1962 it was nationalized and therefore became a public sector’s companyf industry till the privatization in 1997. It is one of the first companies that were privatized due to its profits, as they reached 5 million Egyptian pounds in 1997, in addition to bank deposits and stocks of 2.5 million Egyptian pounds, spare parts stock of 9 million pounds, and waste stock valued 10 million pounds. I mention those figures to say how successful was the company. In the process of privatization, 10% of the shares were dedicated to employees, 15% to the Holding Company for chemical industries, and 75% to investors.

There were many fears and worries indeed, but one of my characteristics is that I insist on achiepapermiddleast 23


• What about SIMO mill and the production lines? On its production line, SIMO produces duplex and manila board, as well as kraft with 40 tons/day capacity. The equipment was imported from Germany. The second production line is for producing grey board with 20 tons/day capacity. The line is also from a German manufacturer, and it is one of the best machines in the Middle East. The third production line is for producing egg trays with capacity 60,000 units/day. The fourth line is producing core, and is also one of the best and newest production lines in the Middle East, with a very high capacity. Besides, we are equipped with boilers from Japan of 20 tons/day capacity, a compressors station with 6 compressors, an electric station and a water station. Our production site is 30 acres wide.

• How would value the company? What is its workforce? The last valuation dates back to 1997, before privatization. However, we can assess that the land only is worth 350 million Egyptian pounds. SIMO employs 610 people who work on three shifts 24-hours.

• What are your are schemes and goals, considering the tough circumstances we are going through? My first goal is to use the great enthusiastic spirit that exists now between all the employees to motivate them to do their best so we can all gain success with SIMO. The next goals are to increase production capacity, overcome the lack of raw materials by cooperating with new suppliers either from private sector, public sector or auctions. We trust that the current crisis will end soon. Also we’ll sell all the stock production we have in our stores, and there is a new plan which is using the printing machines we have in our companies, these machines can do all the printing steps. They have stopped 15 years ago now, but this ac24 papermiddleast

tivity could be reactivated.

• Do you plans to develop the mill? There was a developing project for our mill but it wasn’t completed. Now we have a new project. The aim is to double the capacity by increasing the production of the 3 machines by 30%. This new developing project will cost less.

• You started your work at SIMO in 1975 when Egypt had been through a war, and now you hold your new position after 25th January revolution, how does it affect you? Of course January’s revolution plays a great role in our history. After it took place there was a great change in how people think and how to choose the suitable candidates for different job positions. It is now more based on the competence, and well qualified employees will be holding the leading positions. This revolution aims to achieve some goals such are freedom and social justice, and these goals become a general goal for all Egyptian companies and authorities at every level. The young people of Egypt who started this revolution should have all of our respect.

• What is January’s revolution effect on you? It affects me in a personal way because it really


comforts me in my determination to achieve my goals. As for SIMO, there is a great spirit between us all to raise the company to the highest standards and gain benefits for all of us. The whole staff is working hard to upgrade our work. Let me tell you a story that happened in our mill and that is a proof of that spirit that. After the revolution started, we suffered from the lack of raw materials. So all the employees started to bring everything used paper they could find from their own homes to contribute in solving this problem. Even if it was on a small range but it shows how people want to help and how they are affected by the revolutionary spirit.

• A final word you want to say? SIMO is a very great company in the Arabian paper industry, and we, as manager, are doing our best to improve our situation in all levels, such as employees’ well-being and income. The long lasting existence of our company on the Arabic market, and all of these goals of growth will not be a reality without the dedication of the employees themselves and that great enthusiasm they have is the real treasure of SIMO. 


Technology

New Dryer fabrics based on Smart Surface Technology™ by Dieter Kuckart, Technical Product Manager Dryer - Europe AstenJohnson GmbH Eupen/Belgium

stenJohnson is leading the way regarding cognitions of advantages of intelligently structured fabric surfaces. This is shown by the adaptation of different products to the respective field of application. The dryer fabric design MicroTecTM is taking, due to its broad spectrum of use with more than 2000 fabrics worldwide on the market, an important role among the innovative products of our product range. The Smart Surface Technology™ design MicroTec™ takes advantage of the effect of the controlled surface roughness through longitudinal grooved monofi laments in the machine direction for the improvement of the contamination management in the dryer section.

A

Contamination management The well-known effect of the controlled roughness of microstructures on clean ability (Lotus leaf effect) improves in the industrial application the cleaning behaviour of Smart Surface Technology™ fabrics as well. Already in the early stage, the fine structured yarn shape of the MD yarns provides an improved 26 papermiddleast

contamination management by reducing the surface for the adhesion of dirt particles. Furthermore, thanks to the intelligently modifi ed fabric surface of the patented Asten-Johnson MicroTec design smaller particles detach in an early stage of agglomeration forming (self cleaning effect). This happens before a critical size of the dirt agglomeration is reached, which could lead to thin places or less good printing quality of the paper. The thereby reached easier-toclean surface is strengthened by grooved channels which help to evacuate the dirt particles. All this leads to a longer lifetime of the fabric in the paper machine.


Successful further developments In the meantime, AstenJohnson’s Smart Surface Technology™ product family has been extended by the new designs Clean-Tec™ and SpeedTec™. In the case of the new design CleanTec™ the fabric construction has been modified so that the dryer fabric offers a still higher number of contact points and a pronounced surface topography. Thereby the contamination management for particularly persistent problems is getting improved. In a first field trial, CleanTec™ was put into use in a modern, testliner and fl uting producing paper machine with a speed range of 1100-1389 mpm in the 6th single tier position. As it was the first position in the dryer section without high pressure cleaning system, there was the issue that a high amount of contamination was permanently deposited on the fabric. By using the CleanTec™ design, not only the accumulation of dirt could be reduced, but the lifetime could be doubled as well! This became possible as the air permeability decrease with the CleanTec™ design could be delayed significantly.

son design CleanTec™ could prevent the problem of passing on the contamination to the outside roll in the critical 3rd position – compared to the predecessor designs – and in addition ensure a perfect cleanness of the dryer fabric.

Due to these extremely positive fi eld trials he air permeability range of CleanTec™ has been expanded so that the application spectrum could be enlarged. Here the contact surface for the expanded perm range is kept constant through constructive techniques.

First class products and services

In a further critical application, indeed the production of bleached MG-Kraft paper (65gr/sqm), the additional chemical fabric cleaning in the 1st Uno Run position could be made redundant by using the the Clean-Tec™ design due to the improved contamination management.

These new dryer fabric developments strengthen AstenJohnson’s reputation as an innovative manufacturer of high performance dryer fabrics meeting the demanding and complex requirements of modern paper machines day after day. Therefore AstenJohnson offers a wide range of customized products for any challenge in the dryer section. Another complementary strength of Asten- Johnson is our first class service, not only in the dry end but in the wet end as well, whichmakes us a preferred partner for the paper-makers when highest quality and efficiency are required. Our worldwide active experienced application engineers do not only carry out standard services in the fields of measuring echnique, consultancy, troubleshooting and training but offer competent assistance for the optimization of machine performance and paper quality as  well.

In the area of coated fi nepaper the Asten-Johnpapermiddleast 27


Technology

Measurement and control of optical brighteners using inline sensor technology Klaus KUNSCHERT1, Heinz ZIEGLER1, Helmut LEYERER2 (1 University of Applied Sciences, Faculty of Paper Technology, Munich, 2 BTG Instruments GmbH, Herrsching)

Abstract The appearance of graphical paper is determined by its brightness and color which is adjusted by opti-cal brightening agents (OBAs) and dyes. This addition of OBAs and dyes is commonly controlled and monitored according to the scanner values of the pope roller. This common practice has many flaws including the delay between dosage of the additives and the actual measurement, the danger of overdosage when a change in furnish occurs as well as the fact that during a sheet break there is no value which the dosage can be related to as the last measured value does not reflect the reality of the process. In the scope of a diploma thesis it could be demonstrated how, with help of the inline sensor BT-5400 UV, OBA and dye can be measured and controlled. In a practical example the sensor was installed after the deculator of a fine paper machine. The OBA and two dyes were dosed directly into the pulp suspension as well as a further OBA dosage in the size press. The time between dosage, inline meas-urement and pope measurement amounts to less than 10 minutes. This allows for a control loop with fast reaction. The real-time measurement of OBA and color allows a reduction of broke production, faster grade changes, avoidance of over- or underdosing and close control during web breaks where scanner values are not available. 28 papermiddleast

The installation of the inline sensor BT-5400 UV in combination with a control loop enables a fast amortization of the investment and an increase in productivity and paper quality.

Keywords Optical brightening agent, color, dye, brightness, inline sensor, control loop, savings 1 - Introduction and objective Optical brightening agents are substances which adsorb non-visible UV light (with a wave length of 300 – 400 nm) and reflect this as visible blue light with a wavelength between 400 and 450 nm. OBAs are generally anionic, watersoluble and colorless. The brighteners used for papermaking all have the same basis molecule based on Diaminostilbene-disulfonic acid. OBAs can be categorized according to the number of sulphonic acid groups (Di-, tetra- or hexasulphonated). The smaller the number of groups, the less affinity the brightener has for cellulose fibers. Di-sulphonated groups are generally dosed directly to the stock and hexa-sulphonated OBAs are dosed in the size press or to coating color. Tetra-sulphonated types are allrounders. In grades with a high brightness demand OBAs are added both internally and to the surface. The aim of this thesis was to examine the optical brightener dosage and its effect through inline process measurement. It should be checked if a control loop of the brightening agent leads


to a higher paper quality and lower production costs. The analysis was carried out on paper machine 6 (PM 6) in the Sappi Biberist mill in Switzerland. Currently the dosage of the OBA, blue and violet dyes at PM 6 is adjusted manually according to the values of the pope paper scanner. If the value delivered is too high the operator slows the rotation frequency of the pump, thus adding less brightening agent to the system. Is the value measured too low, the frequency of the pump is increased. Due to the late measurement of the pope scanner the operator only sees the result of his actions after a delay. Addi-tionally, the operator has no value which to control the dosage by if there is a web break. A simultaneous measurement of the values and recording of the dosage of OBA should be achieved by the installation of the BT-5400 UV in the scope of the thesis. The instrument can measure fluorescence as well as the color (L*a*b*) of the pulp suspension inline and in real-time. Through the installation in a suitable position the optical brightening agent can be dosed more precisely according to the exact specification of each grade. Thanks to this, OBA sav-ings can be achieved.

the USA find a paper with a more yellow shade to be more appealing. In reality this means that in Europe a paper that reflects all light (and is practically “white”) is not seen or per-ceived to be as white as a paper which is slightly blue. There are approximately 14 methods to describe brightness/whiteness. The most popular are the R457 Brightness (ISO standard 2470) and the CIE Brightness (ISO standard 11475). Color can be described by the CIE L*a*b* color space (Fig. 1). This is a three-dimensional space which covers all observable color and is based on the concept of physical contrary col-ors. On the a*-axis the negative direction describes how green the color is and the positive direction how red the color is. On the b*-axis the negative direction describes how blue the color is and the positive direction how yellow the color is. The L*-value indicates the dark-ness/brightness of a color with L*=0 being black and L*=100 being white. [1]

Further advantages of this online measurement are faster and securer grade changes. Through permanent process monitoring errors can be recognized and eliminated almost immediately, reducing the production of broke and avoiding unnecessary costs. Another aim of the thesis was to prove the economic efficiency of a BT-5400 UV sensor and to show that a more constant paper quality and lower costs can be achieved by automation of the optical brightening agent dosage. 2 - Brightness and color measurement 2.1 General The color white is a subjective perception. In Europe most people find a paper or material with a light blue tint to be white. This however varies from country to country. People living in

Fig. 1: L*a*b* Color space [2]

2.2 - Inline measurement with the BT-5400 UV The BT-5400 UV is part of the ”smart transmitter”- series from BTG and is controlled by an intelligent microprocessor. The sensor can be connected to any point of a 4-20 mA DCS. It can be used in all pulp furnishes. The BT-5400 UV was especially designed for monitoring processes such as bleaching, deinking or coloring pulp. Through intelligent algorithms the transmitter can control process papermiddleast 29


pa-rameters. The BT has five analogue signals which it sends to the DCS. These can be calibrated to any optical measurement including L*a*b* values, brightness, ERIC (effective residual ink concentration) or fluorescence. [3] The measurement is based on reflection. The optical properties of the fibers are measured using light from LEDs with different wavelengths (red, green, blue, UV, infrared). The UV LED ensures that the effect of fluorescence can be measured. The reflected light is captured by four detectors. This optical signal is carried to the processor where it is converted to an analogue signal. 2.3 Installation One of the most critical factors for accurate measurements of the BT-5400 UV is the installa-tion position; most importantly there should be no air present in the pulp suspension. Air would deflect light that should be reflected and measured. Furthermore, a fairly constant con-sistency between 1-4% provides optimal measuring conditions. Stock at very low consisten-cies (below 0.5%) can provide problems if there is a high turbidity. At too high consistency the danger of air entrapments is present. The paper machine in Biberist is a fourdrinier machine and has a dandy roll to improve two-sidedness. It produces 34 different grades of woodfree uncoated paper with varying color, brightness and furnish.

The signals of the BT 5400 UV for PM 6 were calibrated in accordance with the mills most important specifications to measure the following properties: Signal 1 – R457 brightness without UV (% ISO) Signal 2 – R457 brightness with UV (% ISO) Signal 3 – a*-value Signal 4 – b*-value Signal 5 – Fluorescence (% ISO) To determine the installation point for the sensor and identify possible interferences, a wet end survey was conducted. Through this analysis the process conditions surrounding additives, OBA and runnability could be examined. Under the given conditions it was best to place the BT-5400 UV into the accept pipe of the deculator (Fig. 2). The advantage of this measuring point is that the installation can occur without any alterations to the current approach flow. The educated assumption that the OBA had enough time to attach to the fiber before arriving at the measuring point proved correct in later laboratory tests. Another advantage of this position is that there would be no air in the stock after the deculator and that the consistency is rather constant.

Machine data: • Speed : 600 m/min • Width : 3,40 m • Production : 71.000 t/a • Size press (with OBA)

Brightness, color and furnishes: • Brightness : 90 to 112 % ISO • a* Value : - 0,2 to + 4,3 • b* Value : - 19 to + 2 • Filler : GCC, PCC • Pulp : Eucalyptus, Birch, Pine • Different size press recipes 30 papermiddleast

Fig. 2: Installation point in a simplified flow sheet of PM6


3 - Effects of OBA on the brightness and color of different paper grades 3.1 Development of brightness It is interesting to see that the fresh pulp slush already has a fluorescence of 3% ISO. This is mainly due to the fact that the pulp is dissolved in white water, which already contains a high portion of unused OBA that did not attach itself to the fiber. Another reason is the phenomenon that the bleaching process causes minor fluorescence in pulp. The stock from the machine chest shows an increase of 12% ISO. This results from the addition of broke. The broke is already white and brings in additional OBA which has not bonded with the fibers, both effects causing the increase in brightness. After the addition of optical brightening agent, white water and filler, the brightness increases a further 7% ISO. From the brightness without UV it can be seen that the filler contributes about 1.5% ISO to the total brightness.

The broke has the highest brightness with 107% ISO. One reason for this is that the OBA has the longest time to attach to the fibers, another that the broke actually contains the highest amount of OBA. This high amount is due to the OBA already attached to the broke as well as in the white water, which dilutes the dried broke. Both these factors and the long reaction time result in this high brightness. A savings potential of OBA can be seen when looking at the broke contribution percentage of 11% (Fig. 4). If the addition of broke to the furnish increases, the less optical brightener is needed. An inline measurement would automatically recognize this and dose less OBA. OBA which does not attach to the fiber or which is overdosed remains in the system (white water) and is used again when diluting the stock suspension. An inline measurement of the brightness (hence indirectly a measurement of OBA) would recognize if surplus OBA is pre-sent in the system and could further save fresh OBA. 3.2 Effect of internally dosed OBA

Fig. 3: Development of brightness

Fig. 4: Factors influencing the brightness

Illustrated in Fig. 5, is the average dosage of OBA (in liters per hour) and the average fluores-cence effect (in % ISO) in different grades. It can be seen that to get a similar effect of the OBA, different grades require different amount of OBA. This is due to the different furnishes, fillers and other properties of these grades. The paper grade “Polar� for example has a very low b*-value of -19. To achieve this low blue value much color must be added making the stock darker. More OBA is then needed to compensate this effect and brighten the paper again. To examine the effect of optical brightener on the color space values, sheets with different OBA-contents were formed in the laboratory and a*- and b*values measured, with and with-out UV. Consequently, the sheets formed in the lab do not show the influence of the size press. Small variations of OBA only repapermiddleast 31


sulted in a small change of the b*-value. Even less of an effect could be seen in the a*-value. The reason for the a*-value being less sensitive, is that OBA shows its effect in the blue wavelength spectrum (converting UV light to visible blue light). No significant effect can be seen in the a*-value as it is measured in the red/green wavelength spectrum. 3.3 Effect of OBA in the size press

fect on whiter base papers. This can be seen as a type of “buffer” effect. Another reason could be that a maximum brightness of 112% ISO can be reached and that by some grades the OBA is overdosed in the wet end. If this would be the case the final brightness can be controlled by the dosage in the wet end. A further possibility would be different penetration properties of the base paper. Due to lack of time the effect could not be examined further in the scope of the thesis.

The size press recipe is constant for all grades except for the grades “Star” and “Neve”. In Fig. 6 the red bars show the average brightness of the base paper of different grades. This var-ies by up to 2% ISO due to different furnishes, fillers and color. The blue bar shows the dif-ference between the base paper and the sized paper. The sized paper of course has the specifi-cation of the finished product (112% ISO).

Fig. 7 shows that the OBA in the size press causes a constant decrease of the b*-value of about 2.8 in all grades. In the grade “Star” this is not the case as this is the only grade with a different size press recipe.

The grades “Pro” and “Top” are good examples. These have a difference in base paper brightness of 2% ISO but the same size press mixture gives them both 112% ISO brightness. In other words the OBA in the size press is 2% ISO more effective in the grade “Pro” than in the grade “Top”.

4 - Potential savings

This effect can have different causes. One explanation can be that the OBA has a weaker ef-

Fig. 5: OBAs effect on brightness in different grades 32 papermiddleast

The difference between base paper and sized paper, regarding the b*-value, can therefore be seen as an offset when looking into an automation.

To justify the investment made in an instrument, clear financial benefits must be proven. These can partly be shown with direct cost savings and partly with other benefits and advantages.

Fig. 6: Size press effect on the paper brightness


4.3 Faster grade changes Due to the fact that the machine operators adjust the dosage by the scanner value for the paper to be in specification, the result of their actions can only be seen five minutes later. If further adjustment is needed another five minutes is required and so on. By using inline instrumenta-tion the delay of five minutes can be cut by at least 60%. This increase in machine efficiency and reduction in broke shows a potential of â‚Ź40,000 annually. 4.4 Premature error recognition and prevention Fig. 7: Effect of the size press on the b*-value

4.1 Quicker response time Commonly, the machine operator adjusts the OBA and color dosage according to the signal of the measurement given by the scanner at the pope reel. The result of this correc-tion/adjustment can only be seen five minutes later. This delay can be very problematic. Us-ing an inline measurement, the changes can be seen already 90 seconds after the change has been made, allowing the delay to be reduced by well over 60%. 4.2 OBA overdosing Due to the fact that the machine operator cannot constantly check whether the dye and OBA dosages are at their optimum, it could often be seen that only one adjustment was made during the start of each produced grade and left for the entire grade production as long as the reel measurement was in specification. Many trials proved that the OBA dosage could be decreased without a negative effect on the brightness. This was proven by the pope reel measurement as well as the instrument. Experience has shown a possible average reduction of at least 2 l/h. If this is achieved the savings reached (in accordance to production, OBA price, etc.) would be 13 tons OBA which amount to about â‚Ź13,000 annually.

During a night shift there was a technical defect on the brightness and color measurement on the pope reel scanner. Without this measurement there was no value for operators to make adjustments by. Due to this the machine had to be shut down until the defect could be fixed in the morning. If there had been a measurement in the stock there would have been a value to go by and a shutdown could have been avoided. On three separate occasions the outlet of the blue dye plugged. The operators could only notice this (in the earliest case) five minutes after it occurred. This caused unnecessary broke production until the color was back into specification. With an earlier inline measurement and automation this could have been avoided. Errors like these may not happen on a daily basis but do occur, creating costs that all add up annually. This must definitely be considered when defining the value of inline instrumentation and automation. 4.5 New trial possibilities Through a measurement of brightness and color in the stock, new possibilities for trials are created. Different brightener types, dyes, colors or the influence of the size press can be measured and recorded in real-time. Size press recipes can be optimized as there is a direct papermiddleast 33


comparison to the base paper values. This application should also be considered when thinking about the value of such an instrument. 5 - Summary The color and cost of copy paper are the most important aspects influencing the consumer’s purchasing decision. These properties can easily and cost-effectively be influenced using optical brightening agents and dyes. The amount of OBA which is in a paper machine system is rarely constant as it is influenced by the furnish, amount of broke used, retention of the sys-tem and possibly overdosing of the additive. The common practice of machine staff monitor-ing and adjusting brightness and color according to the measurement of the pope reel scanner is not optimal for two reasons. For one, the staff cannot constantly monitor and manually ad-just the OBA-dosage to adhere to the product specification. Secondly, alterations and process changes can only be detected after a fairly long delay. A brightness analysis showed that in this particular case, broke used in the furnish contributes around 11% of the total brightness, and white water (with re-circulated OBA) and fresh OBA contribute around 7% of the final paper brightness. Broke has the highest concentration of OBA on the fiber and OBA in solution (and that has not attached to the fiber).

An interesting observation made during the thesis which still has to be examined is the equalizing effect the size press has regarding brightness. The brightness of the base varies between 104 and 107% ISO. The size press (using the same size recipe with OBA) equalizes all base papers to 112% ISO. This effect can be explained by either an overdosage of OBA in the size press or different penetration of the OBA into the sheet.

34 papermiddleast

Through the early measurement and control of brightness two main saving potentials are created. One of these is that grade changes can be performed more accurately and faster, saving costs of broke production which amounts to â‚Ź40,000 annually. The second potential is that of avoiding overdosing OBA. A minimum of 2 l/h optical brightening agent can be saved by optimized dosing resulting in a saving of â‚Ź13,000 annually. The premature error recognition facilitating a reduction in broke production and downtime, as well as the new possibility of product and process optimization must be considered as well. The investment in the BT-5400 UV shows a return on investment within six months. The requirements for automation of the OBA dosage are fulfilled. The sensor delivers correct values for all produced grades. Seeing that during automation the brightness is controlled within certain limits, there is no negative effect on the a*- or b*-value. Due to the stock vary-ing in brightness (caused by different filler and furnish) and the fact that the size press levels the final brightness, the only thing still required to implement automation, are the target val-ues  for each grade.

Literature [1].PAULER, Nils. Optische Eigenschaften von Papier, Lorentzen & Wettre 1998. ISBN 9197176583. [2]. http://www.heise.de/foto/artikel/Immer-noch-exotisch-L-a-b228542.html. - [Online] [3]. BTG Instruments GmbH. User Manual BT 5400 UV BTG Instruments GmbH, 2007.


Products and solutions

Safety and efficiency through total tail control An unreliable and slow manual tail threading process, a high volume of threading waste and other tail threading problems cause costly downtime for many production lines, and can also compromise operator safety. Upgrading the process by evaluating the current situation and finding the best solutions for automated, reliable and fast tail threading is a worthwhile investment. Marika Mattila

Steps to efficient and safe tail threading To hit on the most optimal solution, the first step is to evaluate the current tail threading process – the condition of the equipment and the efficiency of the process – to identify problem areas. The optimal upgrade solutions can then be found. Total tail control is about managing the whole process around tail threading, not just the equipment.

Correct solutions for each need Metso’s advanced tail threading solutions are suitable for all types of paper, board and tissue machines. This has been achieved through process know-how and expertise gained in various tail threading projects for both new lines and upgrades. Ropeless tail threading conveyors represent the most advanced threading solutions. The conveyors’ vacuum is created by foil nozzles and the rotating belt controls the tail exceptionally well, even during process variations. Combined with a digital break recording and web monitoring system, the information received provides a very useful tool for troubleshooting and analyzing breaks. This 36 papermiddleast

keeps the paper machine consistently running at its top efficiency. FoilForce1 is the flagship of Metso’s conveyor tail threading technology. Over 1,400 units have been sold worldwide. Based on the tail doctor technology, TailDoc is an outstanding solution for automated tail threading in double-fabric dryer sections. The doctor blade separates the sheet tail from the dryer cylinder surface and compressed air is blown under the tail to guide it to the next fabric nip. It is easy to replace the existing threading system with TailDoc due to its minimal space requirements.

Having total tail control throughout the machine clearly enhances production line efficiency.


TailDoc works invariably well at start-ups and in exceptional situations where rope-assisted tail threading is difficult. TailDoc allows greater moiture variations and is also insensitive to speed changes. A suitable combination of tail threading systems and tail cutting devices are available for every grade and machine geometry. Tail cutting is performed with water jets or mechanical cutters, providing better controllability and uniform tail quality for the tail threading process.

Tail threading services secure operational efficiency and reliability Proper tail threading services will maintain tail threading efficiency at their target levels and allow papermakers to focus on the core aspects

Metso’s automated tail threading solutions : Benefits visible on bottom lines Significantly shorter tail threading time compared to conventional rope systems.Enhanced operator and mechanical safety by eliminating close calls and rope accidents.Increased production line efficiency and reduced unexpected downtime.Savings in energy and maintenance costs.

of their business, such as quality development. With a tail threading study, the main problem areas in the existing process can be identified and eliminated with the help of Metso’s experts and their recommendations. Correct preventive maintenance actions bring savings in maintenance costs and ensure equipment availability and reliability. A Metso service agreement is designed to secure the

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optimal operation of the equipment, reduce threading times and improve maintenance efficiency. It is the right tool with which to better manage overall operations around the tail threading process in a systematic way.

Economical tail threading improvement investment Tail threading improvement investments where unreliable and slow tail threading systems are replaced with automated and safe solutions are generally very cost-effective and the related payback periods tend to be short. In a case where the threading time was cut by one-third through replacing the existing rope system with TailDoc tail threading units in the double-fabric area, the investment’s payback time was just a few months – and the amount of tail threading broke was diminished.In addition to safer and more time-efficient operation, an upgraded tail threading system saves energy. Upgrading the tail threading process on a newsprint machine with a trim width of 8.0 m reduced the break time by about 30%, which meant annual savings of EUR 130,000 in energy costs.

Veli-Pekka Koljonen

“We are dedicated to developing reliable, simple and easy-to-use solutions for hands-free tail threading. Consequently, this means a safe and seamless threading process for operators,” says Veli-Pekka Koljonen, Metso’s tail threading specialist.

Metso provides full coverage of tail threading solutions throughout the production line. 38 papermiddleast


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