Leap into new dimensions through foresight and trust

ANDRITZ and MM Frohnleiten GmbH are global leaders in their respective industries. Only 20 kilometers apart, they can look back on a decade of collaboration. This proximity and shared history create the trust needed to successfully realize demanding projects requiring extensive know-how.

In 2015, the two companies launched an ambitious project: to further optimize the already productive KM3 board machine. This machine produces folding box board in chromo duplex and triplex quality of 230 to 450 g/m2 and achieves a speed of 800 m/min with a wire width of 5 m. The goal was to reduce the specific energy consumption, increase quality of the end product, and boost productivity across the entire product range.

CHALLENGES AND INNOVATIVE SOLUTIONS

One particular challenge was realizing a higher dewatering capacity in the middle layer without significant extension of the wire section as well as the installation of an additional layer with the new PrimeFlow AT two-layer headbox in the specified space. ANDRITZ once again proved its solution expertise: The existing, around 30-year-old headboxes from the other three layers were overhauled at the ANDRITZ workshop and made fit for the future. Georg-Michael Sautter, Director Key Accounts Paper & Board at ANDRITZ, was confident in the ability to overcome this challenge by taking an innovative approach, “Before this, we hadn’t installed any two-layer headboxes in a multi-layer machine. But thanks to good cooperation, we were able to convince MM that our hybrid formers would enable such a modification without having to increase the size of the middle layer. We also installed a complete fifth approach flow for the additional layer in the basement, which was quite a perfect fit.”

Over the long term, MM will also benefit from the first ever installation of the ANDRITZ-developed “VIB TriStream” steam blow box. The application of steam, which is optimized using three uninterrupted vacuum levels, increases the temperature of the board web, thus significantly improving the dry content after the press. The specific overall steam consumption in the dryer section is reduced as a result. This saves energy and minimizes the carbon footprint.

EXPERIENCE AND FLEXIBILITY: ESSENTIAL SUCCESS FACTORS

The project was preceded by a long, extensive planning phase. “Still – and this cannot be avoided with such large tasks – there were situations where we faced unplanned deviations. Although we planned and discussed the holes to anchor the foundation plates of the press down to the last detail, and even produced drilling templates, unfortunately the holes still didn’t initially fit,” reminisces Johannes Holzer, Project Manager at MM. In these kinds of situations, everyone had to work together to be successful in the long run.

The rebuild of the KM3 was a milestone on MM’s path towards conserving resources and boosting energy efficiency. “The rebuild was a key part of a big location development project with a total investment sum of 100 million euros,” describes Adrian Kaiser, Head of Technical Department at MM. “Before the rebuild, the stock preparation system had to be gradually adapted to the new requirements in just under two years. Also, everything on the equipment side had to be finished when the machine was again started up,”explained Kaiser. And then it became clear that the planning was not only thorough – but the rebuild work itself was also extremely precise. “I really have to compliment ANDRITZ on the fact that they organized this rebuild with us in a very compact way and that everything worked almost exactly to the day.”

Georg-Michael Sautter reciprocated this appreciation, “The project continued to grow in planning discussions. Our partner MM was always open to innovations. Of course, we constantly strive to be innovative. Because only those who are ready for something new can enjoy success at the end of the day. But this requires the customer’s trust and their shared belief that it will ultimately work.”

INTERPERSONAL COOPERATION PAIRED WITH A FOCUS ON SOLUTIONS

When problems occur unexpectedly, it becomes especially clear how well the cooperation between the project partners and employees works. “In the project management team, we were pleasantly surprised by how quickly and easily the project members overcame unforeseen challenges,” said Holzer. “Solutions were found before the topics were brought up in the team meeting. It was very remarkable.”

“Problems like this are inevitable,” states Sautter. “In such cases, we benefit from the solutionoriented approach of our employees – for example, when a colleague takes a part to the workshop in Graz, repairs it there, and immediately brings it back again.”

FLEXIBLE SOLUTIONS AND FUTURE POTENTIALS

For Ernst Kerschhofer, Vice President Paper Machine Service at ANDRITZ, a flexible approach was an important factor in modernizing the headboxes. “The very tight deadline was only possible thanks to optimized logistics. When rebuilding such complex system parts, you always have to expect unforeseen challenges, but we managed to keep to the schedule,” emphasizes Kerschhofer.

ANDRITZ’focus on always finding flexible solutions for the customer pays off when changes have to be made at the last minute. “We were still able to integrate new technologies into the rebuild relatively late in the process,” adds Holzer. And not only ANDRITZ and MM benefit from overcoming all these challenges. All of ANDRITZ's other customers do, too. “Every day is a school day,” emphasizes Andreas Pfennich, Senior Project Manager Paper & Board at ANDRITZ. “Each project is complex and challenging. No matter how much experience you already have, you always take away something new for future projects.”

SUSTAINABILITY AND EFFICIENCY: THE KEY TO SUCCESS

The goal of modernizing the KM3 was to make the machine more energy-efficient. “Our main aspects were always to save energy and water and improve process cycles all while continuing to increase product quality,” explains Kaiser. Bottlenecks were also eliminated. The success is already evident: Steam consumption was decreased by 10% in the drying section. “The machine was already in a very good range in that area,” states Kerschhofer, comparing with other industrial plants. “But now we’ve achieved record-breaking values, even world market leader values!”

For companies like MM, sustainability is becoming increasingly important. On the one hand because sustainability cuts costs over the long term, and on the other because it’s a selling point that’s becoming stronger on the global market. “Customers, too, are more often asking for sustainability reports. As a cartonboard producer, recycling is part of our main business and one of our goals. Everything moving in this direction is accepted and desired in the markets. This has been the case in Europe for quite some time now, but we are now also seeing trends overseas, too. Demand is growing on the American markets especially, where this was almost impossible to imagine in the past. The environment and recycling mindset is gaining prevalence there as well,” explains Georg Hammer, Head of Production at MM Frohnleiten.

PROGRESS AND OUTLOOK

Despite successful start-up of the KM3 after the rebuild, it is clear that the overarching location development project isn’t complete yet. “A 10% decrease in steam is a considerable success,” says a satisfied Kaiser. But there is still room for improvement. “Now, after putting the KM3 back into operation, we will review technical and quality-relevant data. We’ll have to exercise some patience before we have conclusive reference values. But we can already see that there is potential for further optimizations. And that’s where we’ll be needing ANDRITZ again,” concludes Kaiser.