DS Smith's mill in Aschaffenburg, Germany, equips most of wire, breast and drive rolls in PM No. 1's forming section with Voith's CeraGuideB full plasma coating, resulting in increased run time of rolls, lower maintenance costs, longer forming fabric life
January 23, 2014
– DS Smith at Aschaffenburg, Germany, has equipped most of the wire, breast and drive rolls in their forming section of PM 1 with the CeraGuide B full plasma ceramic coating from Voith. Difficult machine conditions, the properties of the machine clothing, as well as the increasingly critical raw material input, had led to severe wear on the former rubber covers of the wire and drive rolls.
In the beginning, the main objective for the switch to ceramic surfaces was the increased run time of the rolls, thus lowering maintenance costs. Soon after start-up, further benefits of the new coatings were observed with forming fabric life being extended by more than 50% in nearly all positions. Additionally, the roll surfaces have maintained their shape and integrity perfectly, especially at the ends, where previous cover fracturing through invasive corrosion has always been present and contributory to fabric damage.
Since CeraGuide B has been installed, forming fabric edge damage is now a thing of the past thanks to a unique roll end and edge radius treatment process, and wire drive stability has been excellent throughout without a single instance of slippage. The longest serving CeraGuide B cover has now been running in the machine for 5 years without interruption on the drive position of the bottom wire, where previous rolls with rubber covers had to be changed after 150 to 400 days of operation.
An additional potential for cost reduction is offered through doctoring in those roll positions. Whereas former rubber covers needed a high amount of lubrication water to avoid wear or damage from the doctor blade, CeraGuide B can be doctored without any lubrication water. For example, on PM 1, 550 l/m/min of doctor lubrication water can be saved per doctoring position. Walther Böhm, technical director at Aschaffenburg, emphasizes that in addition to the water savings, equipment costs for providing that amount of water, like pumps etc, disappear.
Against the background of a more and more critical raw material situation and the resulting sensitivity to wear in the wire section, the market request for CeraGuide B is growing constantly. This coating suits graphical as well as board and packaging applications and has proven its quality in more than 120 installations over the years. Unlike competitor products on the market, CeraGuide B is a full plasma ceramic of utmost hardness without fast wearing epoxy components. Due to its numerous benefits, CeraGuide B shows a return on investment of less than one year in most applications.
DS Smith is one of the leading manufacturers of high quality containerboard in Europe and PM 1 at Aschaffenburg produces more than 280.000 t of testliner and corrugated board annually in a basis weight range from 80-120 g/m².
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Voith Paper is a division of the Voith Group and the leading partner to and pioneer in the paper industry. Through constant innovations, Voith Paper is optimizing the paper manufacturing process, focusing on developing resource-saving products to reduce the use of energy, water, and fibers. Furthermore, Voith Paper offers a broad service portfolio for all sections of the paper manufacturing process.
Voith sets standards in the markets energy, oil & gas, paper, raw materials and transport & automotive. Founded in 1867, Voith employs more than 43,000 people, generates € 5.7 billion in sales, operates in about 50 countries around the world and is today one of the biggest family-owned companies in Europe.