Professional Papermaking 1/2022


RUBRIK Professional Papermaking 1.2022 2

Countdown: ZELLCHEMING-Expo 2022 The program for Expo 2022, which will take place from June 29 to July 1, 2022, as a face-to-face event at the RheinMain CongressCenter (RMCC) in Wiesbaden, has been finalized - and with it, the countdown to the event, which will be held as a live event again after two years, has begun! The lectures will address current approaches of the paper and cellulose fiber-based industry on the way to a climate-friendly bio-economy and will focus on initiatives and lighthouse projects, such as the pioneering investment in a new paper machine by Hamburger Containerboard in Spremberg, Brandenburg, near the GermanPolish border, which also have relevance beyond the industry. Exhibitors are involved via best-practice applications and the latest technologies for process and product innovation. Hybrid event! In view of the positive experiences in the Virtual Days 2021, ZELLCHEMING will further expand its role as a virtual pioneer and organize the Expo 2022 as a hybrid event with digital reach extension. The so-called ZELLCHEMING Virtual Days became the ZELLCHEMING Virtual World, a thematic island on the web where all content can be found, partly already before the Expo, in live stream for online participants during the Expo and as back-up afterwards. ZELLCHEMING Conference Premiere! Quasi as a prelude to a ZELLCHEMING Paper Week, the “ZELLCHEMING Conference – Cellulose-Based Materials” will be held for the first time from June 26 to 29, also in the RMCC in Wiesbaden. The conference bridges the gap between innovative research on cellulose-based and cellulose-derived polymers and scientific work in the field of the most well-known material made of cellulose: paper. The event will feature 25 scientific and technical presentations by internationally renowned speakers, dedicated to the great potential of cellulose. Based on a joint initiative of professors from the Technical University of Darmstadt and the University of Jena, as well as the ZELLCHEMING association with its technical committees, the conference brings together industry and research institutes in the fields of chemistry, physics and engineering and facilitates an active exchange. Young researchers are also actively involved and present their own work as a poster show. See you in Wiesbaden! Dr.-Ing. Kerstin Graf Chief Editor Professional Papermaking 1.2022 3 EDITORIAL

Organ des Akademischen Papieringenieur-Vereins e.V. an der DHBW Karlsruhe Organ des Akademischen Papieringenieur-Vereins an der TU Dresden e.V. Mitteilungsblatt des Vereinigten Papierfachverbandes München e.V. Organ des Papierzentrums Gernsbach Mit den Mitteilungen der Papiertechnischen Stiftung (PTS) München, Heidenau Organ der Vereinigung Gernsbacher Papiermacher e.V. Organ des Akademischen Papieringenieur-Vereins e.V. an der TU Darmstadt Das Papiermacherwappen Die sogenannten „Papierer“ wurden in alter Zeit zusammen mit den Buchdruckern, Buchbindern und Glasern der Gilde der Maler zugeordnet und führten deshalb aucwh das Zeichen dieser Gilde: die Schildchen und den Ochsenkopf. Der geflügelte Ochse war der ständige Begleiter des Evangelisten Lukas, des Schutzheiligen der Maler. Er verdankt diese Ehre einer Verwechslung mit dem Mönch und Maler „il Santo Luca“. Eines der ersten Papierwasserzeichen, wie wir sie auch in Gutenbergs Bibeldrucken vorfinden, ist der Ochsenkopf. Organ des Akademischen PapieringenieurVereins e. V. an der TU Darmstadt Organ des Akademischen PapieringenieurVereins an der TU Dresden e. V. Organ des Akademischen PapieringenieurVereins e. V. an der DHBW Karlsruhe Mitteilungsblatt des Vereinigten Papierfachverbandes München e. V. Organ des Papierzenrtums Gernsbach Organ des Akademischen Papi ingenieur-Vereins e.V. an de DHBW Karlsruhe Organ des Akademischen Papieringenieur-Vereins an der TU Dresden e.V. Mitt ilungsblatt des Vereinigten P pierfachverbandes München e.V. Organ des Papierzentrums Gernsbach Mit d Mitteilungen der Papier ech ischen Stiftung (PTS) Mü chen, Heidenau Organ der Vereinigung Gernsbacher Papiermacher e.V. Organ des Akademischen Papi ringenieur-Vereins e.V. an der TU Darmstadt Organ des Akademischen Pap eringeni ur-V reins e.V. an der DHBW Karlsruhe Organ des Akademische Papiering nieur-Ve eins an der TU D esden e.V. Mitteilungsblatt des Vereinigten Papi rfachverbandes Münch e.V. Organ d s Papierzentrums Gernsbach Mit n Mitteilungen der Pap ertechnischen Stiftung (PTS) München, Heid nau Organ der Vereinigung Gernsbache Papiermacher e.V. Organ des Akademische Papieringeni ur-V reins e.V. n der TU Darmstadt Organ des Akademischen ier genieur-V eins e.V. an der DHBW Karlsruhe Organ A i Papi ring nieur-V reins an der TU Dresde e.V. Mitteilung blatt des Vereinigt n Papierf chverba des München e.V. Orga des Papi rzen ums Gernsbach Mit den Mitteilung n der Papiert ch is n Stiftung (PTS) München, Heid nau Ver Organ A i Papi ringe ieur-Ver ins e.V. an d r TU Darmsta t 11 Digitalization is one of the leading topics of The Institut für Textiltechnik of RWTH Aachen University (ITA). In future, tailor-made solutions for paper industry will be developed. Picture: ANDRITZ 52 Look at the innovative project of Essity to convert agricultural residue into bleached pulp and utilize it in high-quality tissue products. ANDRITZ is a technology partner in making this happen. Picture: RWTH Professional Papermaking 1.2022 4 CONTENTS

71 IMPRINT / SERVICE COVER With VEGA level and pressure sensors, more insight into the process in paper production leads to more precise requirement planning, lower consumption of wood, water, energy, low maintenance costs and forward-looking planning of the warehouse. It is wor th taking a critical look at each individual process, but above all intelligently linking the process data with one another. 60 BVG supplies technological highlights of processing equipment for chemical plants at Palm Paper in Aalen, Germany. DIGITALIZATION 6 More paper from less raw materials Utilizing the digital potential of VEGA sensors in paper processing 10 For a quick and easy ordering process Indian customers rely on the Voith Paper Webshop 11 On the way to digitalization in the paper industry The Institut für Textiltechnik of RWTH Aachen University 14 The Digital Roller Carl KRAFFT & Sons begin their journey towards a digitalized company INTERVIEW 23 Bioeconomy - Quo vadis Increasing sustainability and efficiency of papermaking process 26 Model Paper Factory „The vision of climate-neutral paper production“ 28 The countdown is running! ZELLCHEMING-Expo 2022 in presence again SPECIAL 32 ZELLCHEMING-EXPO 2022 Highlights for visitors TISSUE 52 Essity’s circular innovation A tissue breakthrough using annual sustainable fiber AUTOMATION 56 Testing Technology for Papermaking 4.0 Reliable control of the wet-end in the production process CHEMICAL TECHNOLOGY 58 How paper manufacturers safely store, empty and meter chemicals ProMinent solutions for the pulp and paper industry 60 Strong in a team BVG supplies technological highlights of processing equipment for chemical plants at Palm Paper in Aalen, Germany ROLL SERVICE 63 More security and higher efficiency for roll systems Application technology and services from SchäferRolls PAPER FINISHING 66 Experts for paper finishing Jagenberg Paper celebrates its 10th anniversary SPECIALITY PAPER 68 High standard of competence within the frozen food industry Mondi and ROVEMA work very successfully together Picture: BVG Professional Papermaking 1.2022 5 CONTENTS

To meet society’s demand for paper in the face of ever scarcer resources, production has to be more efficient and thus considerably more sustainable. Digitalization is one of the solutions to this challenge. However, besides a willingness to innovate, this also requires making an effort to fully exploit the still unused potential of many existing solutions. Level and pressure sensors, for example, already possess more intelligence than many suspect. Digitalization is not the first change that aims to make the world of paper production more efficient. Earlier modernization cycles also pursued the goal of leaner processes, to try and deliver greater efficiency. But two factors set digitalization apart from previous initiatives. For one thing, industries in general, including the paper industry, are increasingly pursuing globalization of their businesses. The end products are also becoming increasingly specialized, manufacturing cycles shorter and the customer supplies more fast-paced. Today a company can swap suppliers in the blink of an eye, and its customers, in turn, can redirect their loyalty to another supplier offering more favorable solutions. For paper producers this means: Faster reactions, even more product variants and use raw materials ever more efficiently. Because the production of paper is an extremely resource-­ intensive business, there is enormous potential for savings in almost every one of the numerous process steps – from the wood chip silo to the drying cylinder to wastewater treatment. Deeper process insights lead to more precise demand planning, lower wood, water and energy consumption. The reduction in maintenance inputs enables better forward-planning for labour, machine use and spares holding. It is therefore worth taking a critical look at each individual process, discovering and utilising its existing potential, integrating its process data communication into a higher-level digital and data analysis network. The CURRENT situation A look at the current situation in paper production shows that it is precisely the process data from level and pressure measurement that can be used to set a new course. Typically, in terms of robustness and reliability, today’s sensors meet the high demands of industry. For this reason, analogue measuring instruments with a 4 ... 20 mA connection are the most widely used. And these already contain more process intelligence and digital data than is generally assumed; to date, however, they have only been used in the rarest of cases. Fieldbuses or digital protocols that have been available on the market for a long time, such as HART, Profibus PA or Foundation Fieldbus, are being used, but not across the board. Valuable 2nd data channel usable It pays to get to the bottom of the digital capabilities of existing solutions. Since 2016, VEGA sensors can be supplied equipped or retrofitted with a Bluetooth LE (Low Energy) wireless display and adjustment module with this second, digital data channel, sensors and field devices can already today make a lot of valuable data available. In the paper mill, it not only provides a fast and convenient setup, it can also be used as a status display on the health of the sensor, as well as offering comprehensive diagnostic options. The result is, among other things, minimized downtime – because maintenance and servicing can be planned in advance. More security for people and processes This means that sensors that have been performing well for 20 years can still easily be retrofitted with ‘wireless data intelligence’. All VEGA sensors produced from 2003 onwards can also be quickly retrofitted with this same wireless display and adjustUtilizing the digital potential of VEGA sensors in paper processing More paper from less raw materials Professional Papermaking 1.2022 6 DIGITALIZATION

ment module. The procedure is very simple: Unscrew the sensor lid and ‘plug in’ the new display and adjustment module. No software updates or new settings are required. The sensor can be operated wirelessly via laptop, smartphone or tablet, over distances of between 25 and 50 metres, depending on the transmission quality. The direct advantages for users range from a considerable simplification of work at difficult-to-access measuring points, to the avoidance of process risks due to time-consuming, often complicated on-site procedures. In addition, cleaning of the sensor is avoided, like the sight glass in the lid, which before the conversion had to be cleaned manually to ensure the display was readable. Wireless ensures reliable measurement of stockpiles Stockpiles, e.g. of wood chips, are often filled by a mobile “stacker” conveyor, which usually has a level sensor attached to its underside. The Installation of the wireless adjustment module allows the user to communicate with the sensor from a distance to retrieve the measured values or adjust the sensor. This eliminates the risks of climbing the stacker in order to get near the sensor and read its display. Outdoors, with an unobstructed signal path, the wireless communication can easily reach distances of up to 70 metres. Monitoring, operating the equipment and carrying out maintenance at the stockpile becomes so much safer and faster. What is particularly important for users, however, is that the change makes their overall workload lighter and easier. Not only is the risk of an accident when climbing a tall vessel eliminated, but also the risk of objects like covers or tools falling from height or into the process, a mishap that could endanger safety or bring the plant to a standstill. Not to mention the dirt or foreign objects that can cause problems when cable connections have to be plugged in. All VEGA sensors produced in 2003 or later can be retrofit ted with a wireless display and adjustment module. Using a laptop, smar tphone or tablet, the sensors can now be operated via Bluetooth – this second data channel makes valuable digital data readily available. When measurement data can be read out wirelessly from a distance, work on site is much easier. Cleaning the sensor, or par ts of it, such as the sight glass in the lid, is now unnecessary. Pictures: VEGA Professional Papermaking 1.2022 7 DIGITALIZATION

Wireless sensors fill the gap If only an occasional measurement is necessary, like with mobile IBCs or river level gauging, VEGA recommends using its VEGAPULS Air radar sensors for measurement data acquisition. Mobile or remote measuring points in particular are among the biggest hurdles on the way to an integrated production and supply chain. VEGA easily overcomes over these obstacles with its reliable, stand-alone level sensors based on proven 80-GHz radar technology. The focus is on energy efficiency and perfectly matched components, so that the result can guarantee reliable and autonomous level measurements for 10 years or more. Best practice at DS Smith One of the first users of the technology in paper production was the Dutch company, DS Smith De Hoop B.V. in 2020. They used VEGAPULS Air 23, which has been reliably monitoring the levels in the IBCs ever since. Thanks to radar technology, the level inside the IBCs is possible from the outside. The plastic container does not have to be opened or modified to install the sensor. It’s done easily, in a few simple steps. DS Smith receives the measurement data of the respective liquid levels, regardless of the location of the IBC. The set measuring range is 1.2 metres and the measurement/transmission interval 6 hours. Even when the containers are stacked on top of one another, the VEGA sensor on each individual container records the current level and location several times a day – and transmits this data wirelessly to the cloud. The measurement data can also be transmitted via mobile network (NB-IoT/LTE-M1) to the central control centre or alternatively to the VEGA logistics software “VEGA Inventory System.” DS Smith uses a large number of different chemicals. Thanks to this sensor solution on the IBCs, the re-supply order quantities are now exactly right. Time-consuming “visual checks” and manual ordering processes and special expedited deliveries are a thing of the past. But the company is impressed most of all by the uncomplicated installation of the measuring systems. “We only had to carry out a few simple tasks before the data started arriving, absolutely reliably, at the control centre,” reports Ralf Höll, the product manager responsible at VEGA. “The solution was cheaper, more reliable and, above all, simpler than expected.” The “that’s how it’s going to be” situation But what does the future hold for the paper industry? IO-Link sensors have been used for quite some time in the field of process and mechanical engineering. Also, for standard applications in the paper industry, VEGA products with IO-Link are an optimal solution. They all feature simple wiring, digital communication with simultaneous monitoring, as well as a simple sensor exchange that preserves all existing parameter settings. Of course, these ‘BASIC’ compact sensors do not always offer all the advantages of the more process-oriented ‘PRO’ devices – such as extremely high temperature capability, the extensive process connection range in any material, or different housing options. VEGA will also offer in the future – especially for the higher demanding sensor tasks – two-wire Ethernet-based sensors with an APL (Advanced Physical Layer) to enable the use of digital protocols such as Profinet or EtherNet/IP. With this technology, the digitalization of all processes, from simple to highly complex, will become reality in the very near future. Smart can also be simple More intelligent doesn’t always mean more complicated. On the contrary! With digital data and values in the right places, paper production systems can be monitored, controlled and optimized in a simpler, more transparent and understandable way. Because resource savings, lower maintenance costs and just-in-time logistics are decisive building blocks to achieve more efficient paper production, the level and pressure sensors are key compoVEGA of fers reliable, stand-alone level sensors based on its proven 80-GHz radar technology. What stands out here the most: energy efficiency and perfectly matched components that enable operation for 10 years or more without additional power supply. Professional Papermaking 1.2022 8 DIGITALIZATION

nents in any facility. That’s why VEGA sensors are designed not only monitor and interconnect processes more intelligently, but to also make all the work associated with their deployment easier. Moreover, the instruments optimally support the maintenance staff, allowing them to fully concentrate on their core task: ensuring the most efficient production of the best quality finished products. Time to think about paper in more digital terms Offices were supposed to go paperless already in the 1990s, and in those days efforts were made to even save toilet paper. While the share of graphic paper, used mainly for newspapers, books or office printouts, has actually gone down in recent years, online trade and trends such as “to-go” paper cups and the use of paper as a substitute for plastic now account for the lion’s share of production. Other factors, like the shipping of goods in both standard, and now oversize cartons are fuelling this trend. Since almost every second tree felled in the world today is turned into paper, the efficiency in manufacturing has to be redefined. Digitalization is one of the central building blocks for this. Stand-alone trailblazer: One of the first users of the new, self-sufficient VEGAPULS Air 23 level sensors was the Dutch company DS Smith De Hoop B.V., in 2020. VEGAPULS Air sensors monitor the product levels in IBCs. They’re installed in seconds, because thanks to radar, measurement is possible from outside the container. That means the container does not have to be opened or modified in any way. Professional Papermaking 1.2022 9 DIGITALIZATION

Indian customers rely on the Voith Paper Webshop For a quick and easy ordering process Worldwide, the Voith Paper Webshop is already used by 180 customers. Chandpur Enterprises Ltd. and other India customers have now also opted for the Voith Paper Webshop. A fast, simple and personalized ordering process were the main reasons for the decision. Customers worldwide order products and services in real time in the Voith Paper Webshop. In addition to spare and wear parts, fabrics can also be purchased via the application with just one click for over a year now. Chandpur Enterprises Ltd. has been benefiting from the expansion of the product portfolio in the Voith Paper Webshop since March. „With the help of the personalized menu and the order history, we can now quickly identify our fabrics, order them and track the delivery status around the clock,“ says Mr. Devesh K. Singhal, Technical Director of Chandpur Enterprises Ltd.. „We are very satisfied with the Voith Paper Webshop and the cooperation with the Voith experts, who have been flexible to our requirements.“ In addition to Chandpur Enterprises, other Indian customers have already integrated the Voith Paper Webshop into their ordering process. In total, more than 180 customers already rely on the digital application. In the personalized „My Shop“ section, the paper manufacturers can find all the necessary information from the original and current condition of the equipment as well as the order and quotation history, drawings, manuals and contracts. Mr. Devesh K. Singhal confirms the advantages: „Initially, we were not sure whether we should convert our previous ordering processes to the webshop and digitize them. However, we then decided in favor of the Voith Paper Webshop, because we were completely convinced by the functionality as well as the very clear user guidance. In addition, the onboarding process and subsequent registration of the individual users went smoothly. We are glad to have taken this step.“ The Voith Paper Webshop is characterized by the highest data security standards. Different options can be booked depending on customer requirements. „Our goal is to enable our customers to optimize production with minimized downtimes,“ sums up Mr. Gaurav Singh, Senior Executive Sales & Service India at Voith Paper. „One building block for this is the quick and easy ordering of fabrics. We offer customer-specific solution packages, which we are continuously developing further on a region-specific basis. The integration of the Webshop can be done smoothly for any customer worldwide.“ About the Voith Group The Voith Group is a global technology company. With its broad portfolio of systems, products, services and digital applications, Voith sets standards in the markets of energy, paper, raw materials and transport & automotive. Founded in 1867, the company today has around 20,000 employees, sales of € 4.3 billion and locations in over 60 countries worldwide and is thus one of the larger family-owned companies in Europe. The Group Division Voith Paper is part of the Voith Group. As the full-line supplier to the paper industry, it provides the largest range of technologies, services and products on the market and offers paper manufacturers holistic solutions from a single source. The company’s continuous stream of innovations facilitates resource-conserving production and helps customers minimize their carbon footprint. With its leading automation products and digitalization solutions from the Papermaking 4.0 portfolio, Voith offers its customers state-of-the-art digital technologies to improve plant availability and efficiency for all sections of the production process. New member of the Voith Paper webshop: Chandpur Enterprises Ltd. Picture: Voith Professional Papermaking 1.2022 10 DIGITALIZATION

Textile and paper – two worlds with many similarities: High age structures, lot of person-bound process and plant knowledge, plants from the 90s and high energy consumptions....But opportunities are huge: Already installed control systems for production monitoring are a good base for increasing plant availability, reducing energy and operating costs with advanced digitalization technologies. This fits perfectly with the sustainability and digitalization efforts of both industries! Digitalization is one of the leading topics of The Institut für Textiltechnik of RWTH Aachen University (ITA). A large number of research and industrial projects have been successfully completed in the textile industry. In future, tailor-made solutions for paper industry will also be developed. The Institute and the associated Chair of Textile Technology are part of the Department of Mechanical Engineering at RWTH Aachen University. With Prof. Thomas Gries as the head of the institute, textile-related lectures are held in various bachelor’s and master’s degree courses. Research and service topics of the institute cover the entire process chain from raw materials to semi-finished products and products, as shown in Fig. 2. This product development and integration is connected with the platform-topics of sustainability, innovation and digitalization. The various research topics are carried out by about 120 research associates in 15 departments. They are supported by almost 200 student assistants and about 60 employees in laboratories (textile testing, polymer analysis) and workshops (mechanics, electronics, software and hardware). A fully equipped laboratory with approx. 250 textile machines and test benches covering all textile process stages from spinning to joining is also available. In total, more than 400 employees are financed with a overall budget of approx. 15 million euros mainly earned by publicly funded projects, direct industrial research and mixed forms of the two. In the past, ITA has set a strong focus on development of measurement technologies for industrial production processes. Now, based on this, development and implementation of digital solutions is taking place. A large number of projects addresses Institut für Textiltechnik of RWTH Aachen Univers (Blendedtones) On the way to digitalization in the paper industry The Institut für Textiltechnik of RWTH Aachen University Authors: Rosario Othen (; Christian Möbitz; Frederik Cloppenburg; Thomas Gries Picture: Blendedtones Professional Papermaking 1.2022 11 DIGITALIZATION

the development of online measurement methods for quality inspection, tools for the economic optimization of processes, digital twins and further modelling. These developments often use methods of applied artificial intelligence (AI). In the following, successfully completed and ongoing projects are being described, which are also highly relevant for paper industry. Department Nonwoven Successfully completed projects Certain quality parameters of nonwovens and papers are evaluated according to subjective criteria. A continuous measurement of these subjective criteria, such as formation, by an employee is not reasonable for economic reasons. In the NowoVision research project, an AI-based online monitoring system was developed that was trained to recognize subjective quality features using training data. The AI is able to continuously monitor the trained features in the process and alert the operator in case of deviation. Process control in nonwovens, as in paper production, is often experienced-based. The recording of process conditions and product qualities in combination with AI for data analysis brings numerous advantages: for example, the AutoNoM project, which is funded by the German Federal Ministry of Education and Research, promotes the digitalization of planning and quality management at a manufacturing partner company. The digital infrastructure is being built by other partners, while ITA is designing use cases for the AI. One use case is the development of an algorithm that helps employees identify and fix causes of machine downtime. The central component of the algorithm is based on pattern recognition, such as used for product suggestions in online stores. However, not only technological questions were answered, but also economic ones. For example, in the EasyVlies 4.0 project, AI algorithms were used to develop models to predict the most technologically and economically best operating point. Last but not least, in the DigiTextil project, a holistic – from polymer to nonwoven – and cross-company data analysis was carried out. Key developments here were digital shadows of all processes and intelligent data warehousing. Since wetlaid nonwovens and paper production are very similar and demands on quality properties are also often the same, past, and current projects can also be transferred to the paper industry. First steps towards digitisation in the nonwovens and paper sector A first step in this know-how transfer is being taken by the management of the “Digitalization” working group at the Model Factory Paper (German: Modellfabrik Papier, MFP) in the Düren Innovation Quarter. There, digital tools are created that Research and service topics of the ITA across all process stages (ITA) The ITA in numbers (ITA) Innovation Quar ter in Düren (ITA) Pictures: ITA Professional Papermaking 1.2022 12 DIGITALIZATION

help to save energy requirements in the production process to lower CO2 intensity of paper production. In order to create further synergies of nonwovens and technical papers in the context of the bioeconomy, the ITA is currently planning the Digital Nonwoven Innovation Center, D-NIC, which is not only close to MFP in terms of content, but also next to each other. This will further accelerate the digital transformation in the industry, especially in the region. The development goal is a fully networked technical centre with production facilities for nonwovens and technical papers as a platform for developing production-related AI. Through industry training, the aim is to bring together companies and young professionals to counteract the shortage of skilled workers and high age structures. Last but not least, this will increase the attractiveness of the state of North Rhine-Westphalia for experts in digitalization. Competence Centre Digitisation for SMEs As part of the “Competence Centre for Small and Medium-Sized Businesses 4.0 – Textile Interconnected “ (German: Kompetenzzentrum Mittelstand 4.0 – Textil vernetzt), funded by the German Federal Ministry for Economic Affairs and Climate Action, consulting services are offered to companies on how to further expand digitalization in the company and implement AI applications. Qualifying workshops in which solutions are developed together and participants are being enabled to recognize potentials of digitalization themselves. Corresponding implementation projects are worked on jointly. As part of the expansion of ITA’s competencies in paper technology, the workshop “Paper and AI” on May 18th was aimed specifically at the paper industry. Practical examples from the process and paper industry were shown for possible strategies for the implementation and further digitalization in the company. Subsequent expert sessions also provided opportunity to create individual roadmaps. In short, digitalization is a top priority at ITA. Textiles and paper have many synergies and similar issues. The Know-how gained through research and industry projects on digitalization in the textile industry can be transferred to the paper industry. If digitalization is also a necessary step of sustainable transformation for you, please feel free to contact us! Professional Papermaking 1.2022 13 DIGITALIZATION Carl KRAFFT & Söhne GmbH & Co. KG | Schoellerstraße 164 | 52351 Düren / Germany | For any paper-width an diameters up to 2.500 mm. l consistent wall-thickness l homogenous temperature profile l improved drying capacity l lower energy consumption l bigger paper-width in existing frames Ask – we’ve got the knack! K R A F F T Steel Dryers t h e n e x t g e n e r a t i on Competence in Turning Technologies – The Experts

The Digital Roller Carl KRAFFT & Sons begin their journey towards a digitalized company A conversation with Peter Kayser Pictures: Carl Krafft ABOUT! Peter Kayser was born in 1961. Along with his brother Heiner, he grew up in a paper mill, which was founded in 1805 and has been in the family since 1817.The factory was up and running until the end the 1970s. He completed his studies at the RWTH Aachen (Technical University) Aachen with a degree as a Qualified Engineer (Dipl.-Ing.) of Mechanical Engineering. For 23 years he was in various leading positions in the special vehicle construction industry. Since 2014 he has been a Managing Partner at CKS. His hobbies are music and concerts, and he has a particular weakness for The Rolling Stones and the Beatles. Professional Papermaking 1.2022 14 INTERVIEW

What do you see as your core competence? Today we are a traditional machine builder and equipment supplier for the industrial arena. Wherever a continuous sheet-like product is produced, we can supply guide or process rolls. The worldwide pulp and paper industry is a core industry and we can supply all sizes and types of rolls from headbox to rewinder. Based on the prestigious history of Krafft in the paper capital of Düren Germany, we are now committing ourselves to the development of digital products too. Developing software and hardware and thinking in terms of other business models is a huge and momentous step for us. Are they crazy or visionaries? This is what people could ask about the company that has been earning its money with machine and roller construction for 150 years and who now believe they could, at some point, make more turnover with software than with steel products. It is certainly a very daring move! The plan can definitely be permitted as a scenario with which to sharpen the senses (even if this is certainly not necessary at Krafft). Whether it will actually get that far is, of course, unclear and to be seen but the beginning has been made and the path to a digital future has been laid. Launch of the largest steel dryer cylinder in roll manufacturing. In April 2018, Valmet and krafft Walzen launched the largest steel dryer cylinder in the world for the PM 6 at Palm paper mill in Wörth, Germany. The dryer cylinder, from the #KSD series. (krafft Steel Dryer), was ordered by the Palm paper mill from Valmet to replace a cast iron cylinder installed in 2002. We at krafft selected the in-house “J2B” design as soon as the project scope was defined. Digital technologies have become the key to economic success: Through their use, small and medium-sized enterprises (SMEs) can develop new business models, acquire new customers, gain new customers, or strengthen the loyalty of customers they have already served. Digital transformation is one of the greatest challenges in everyday business today. Current studies show that production companies with small or medium-sized structures often do not yet have a concrete approach to such changes or are still at the very beginning of such considerations. At the Düren-based mechanical engineering company Carl KRAFFT & Söhne, which is better known for its product name KRAFFT WALZEN, we have been thinking about the applicability of new technologies and their concrete use for a long time. In the meantime, initial products have been launched or are about to be introduced to the market. Peter Kayser, Managing Director Technology and Sales, Carl KRAFFT & Söhne GmbH & Co. KG, describes his company’s path into the digital future in this interview. Sensor CARL (Computer-Aided Rollerlogger) In our discussions on digitization, we are always surprised what (digital) things you can do with rollers. Professional Papermaking 1.2022 15 INTERVIEW

The inserted and ribbed base and the screwed on journals are characteristic of the design developed by our experts. This design is the lightest on the market and this plays a key role in the further extending of the advantages at high operating pressures. The shell section was manufactured by the company Eisenbau Krämer (EBK). The dimensions of the #KSD with a diameter of 1,830 mm, a length of 11,150 mm, and a construction speed of 1,800 m/min are very impressive. What is the significance of this project for your company? The Palm steel dryer cylinder was a lighthouse project for us. With the design and construction of this steel drying cylinder, we were able to demonstrate that we have the know-how necessary to build such large cylinders. We had already manufactured a considerable number of smaller #KSD in respectable quantities before. It was the right product at the right time. This resulted in interesting major projects for large and efficient paper machines. We produce 50 to 100 steel drying cylinders (depending on the length) for these machines per year. We are convinced that we have a very competitive product. Initially, however, you came up against limits. The growth in the size of paper manufacturing plants and the change in the product world also require us to make adjustments. This trend, by the way, is to be seen in all the industries we serve. That’s why we are consistently orienting our know-how from plant engineering for paper and board production to new products and product areas. Large investments and extensive modifications were necessary to overcome production and logistical limitations for the production of large rolls with a weight of 50-60 tons/roll and a length of up to 15 meters in length. What investment projects have you implemented? In the past eight years, we have invested over 12 million euros in our company. The highlight of 2021 was a new grinding machine for a diameter of 1,000 mm with a tip width of 13,500 mm and a new balancing bench for large rotors above 30 tons in weight. The extension of our Hall 4 has been completed. This is where we carry out the finishing work, grinding, balancing, assembly on our products and prepare them for shipping. Conversely, we have moved all the long turning machines to another hall (Hall 1) and hope that this will enable us to improve our efficiency due to improved internal logistics. In addition, a large lathe was installed in Hall 2 in Düren. On this CNC machine, we can turn components with a diameter of up to 1,880 mm with a width of 12,000 mm. We are currently starting construction work for a new welding technology centre. Have you come out of this process stronger? Traditionally, we are one of the leading manufacturers of rollers and specialist for rotationally symmetrical components in Europe. Thanks to targeted investments, we have succeeded in achieving an elevation of the customization of our products, for example with regard to drying cylinders, and to increasing our system competence. We have become a partner for large-scale projects in the pulp and paper industry, without losing sight of the smaller, customizable product. The increase in stability and CARLota (Laser Optical Test and Assessment) Heating roll for paper machine covering (15 m long). Professional Papermaking 1.2022 16 INTERVIEW

competence in the areas of technology, production and sales meanwhile enable us to keep a close eye on other growth markets and to think about new technologies and areas of application. Digitization is an example of this. How did the move towards digitization come about? The start is not easy and is accompanied by many loops...not setbacks! You have to mentally try to transfer things from the “digital life” to “the roller”. This leads to the first basic approach towards the development of a sensor for the acquisition of data from non-stationary rolls, such as those used in the paper industry. The sensor is intended to support preventive maintenance and at the same time increase safety in the paper mill. We presented the CARL, as we call the sensor – this stands for Computer-AidedRoller-Logger – some time ago to see what the response would be. The first systems will go live this year. We are collaborating on development with the Aachen University of Applied Sciences (Fachhochschule Aachen) and the sensor is now also the subject matter of a funding project. In the future, all rollers built by you will have will have their own tag. Yes, even before the sensor, a “tag” that we call CARLexa entered the market, a kind of label for the roller. Since October 2021, we have been equipping the first rollers with this tag. This is in line with IOT, i.e. Internet of Things, and is to be rolled out successively to all rollers from our own production. What are the possibilities for the user? CARLexa is the basic building block of the CARLSensor family for the digital roller. Via CARLexa, we provide data stored on the tag (QR and/or RFID), which can be accessed without an Internet connection. This enables the user to retrieve essential roller data from the most remote location in the factory and reliably record and prepare the roll for in-plant use and make the data available for in-plant operations. The marking allows anyone to, for example, with the aid of a smartphone, access the basic data of the component, for example, the manufacturer, the year of manufacture and the corresponding order number. The risk of uncontrolled access to company networks is prevented. The registered users, i.e. our customers, will then be able to view further data in the future, such as the drawing or material test certificates. This is where we begin moving in the area of what is also known as digital twins, and consequently, in cloud services. The CARL-Sensor family continues to grow. In cooperation with our customers, we have been looking for new possibilities for inspecting ground roll surfaces for defects. Our employees from the innovation teams have come up with a solution that we cal l #CARLota: Laser Optical Test and Assessment. In this process, we guide a laser system over specific The U30 team; top: Sven and David (both from CNC machining); Bot tom: Marcel (sales), Daniel and Sebastian (3d design); Alexander (sales) and Marvin (3d design). (3d design); missing: Manuel (balancing technology) and Marcel (production organization). View of Hall 4: The completed extension. Professional Papermaking 1.2022 17 INTERVIEW

A large lathe has been installed in Hall 2 in Düren. roll surfaces and, on the basis of an algorithm, determine the defects in the roll surface by applying an algorithm. The system can be parameterized and can therefore examine almost all rolls with regard to the required properties. It takes us 30 minutes to carry out the inspection of the surface of a dry steel cylinder with approx. 10 meters of bellows. In the process, we generate several 10 million pixels, which are archived for later inspection. For clarification, I recommend a video on our YouTube channel: /UCmOARE3VNquETnDztL8cDLQ #CARLota is in the #CARL Sensorfamily (Computer Aided Roller Logger) and #CARLexa and we are currently looking into whether there are online applications in the paper industry. What additional services do you offer? In order to facilitate handling and gradually expand the range of services for our customers, we are preparing our own “mykrafftroller” app. It is the basis for a cloud service, which should be available from summer 2022. The app will not only provide access to data, but also facilitate a new type of communication between the roller supplier and its customers. This will then also bring about considerable changes in the internal working methods, which is expected to result in faster processing of customer inquiries, the avoidance of errors and, in principle, the expansion of the available data base – “Big Data”, so to speak, a tremendous term that one hardly dare use in connection with rollers. Do you see any other approaches to digitization? Digitization is also to be used in the organization of the manufacturing processes and, above all, quality assurance in the paper industry. For a company that does not think in terms of large series or does not have a continuous assembly line, such topics are not self-evident and are very costly. However, we also have ideas here that could be implemented in our own products in the future. www.kraf f About KRAFFT krafft is one of the leading manufacturers for rollers and a special ist for rotat ional ly symmetr ical components in Europe. The know-how from plant engineering for paper and board production has been consistently oriented to new products: – k rafft Walzen-Rollers – the company’s core brand for rolls, cylinders and drums – krafft Pulleys -Drums for the conveying of bulk materials as drive, tension, and deflection pulleys in conveyor belt systems – krafft Turning Technologies -Turned parts and large turned parts for applications in plant and mechanical engineering, winding mandrels and shafts – krafft Engineering- Engineering and project planning, Turnkey systems – krafft Services -Services, repair, assembly I think we are taking a very courageous and offensive approach to these topics and will be thrilled if this courage is rewarded. Professional Papermaking 1.2022 18 INTERVIEW

In your opinion, what are the current challenges along the way to more sustainable paper production and how can mechanical engineering help? There are several factors to be mentioned here, and they all need to be seen in the context of high cost pressure on paper manufacturers. One very important factor is the availability and quality of the raw material for paper production, i.e., the cellulose fibres and the recycled paper. In Europe, the recycling rate is already at a very high level. Such high recycling rates require a preparation of the recovered paper that is particularly gentle on the fibres, for example, to maintain the strength potential of the raw material. Such technologies and solutions will continue to gain importance as the recycling rate increases, since the quality of the raw material and high-quality stock preparation strongly influence the overall economy and efficiency of the papermaking process. With our BlueLine stock preparation, Voith offers the world’s most resource-conserving process concept on the market. Another factor is to minimize water consumption in paper production. Here, we have made great progress in the past decades by closing the production water cycles step-by-step. This year, Which technologies do you use to support the transformation towards a circular bioeconomy? As a full-line supplier, Voith Paper provides holistic and customer-oriented solutions from a single source, for an efficient and sustainable papermaking process. With the XcelLine paper machines, Voith offers efficient papermaking for every paper grade, and with the innovative BlueLine stock preparation products, customers benefit from maximum efficiency and rawmaterial yield. The digitalization solutions from our Papermaking 4.0 portfolio are playing an increasingly important role in papermaking to maximize resource efficiency and plant availability. The wide range of consumables and spare parts that Voith supplies to the paper industry also makes an important contribution to lowest energy consumption, high machine efficiency and plant availability. In the interview series “Bioeconomy – Quo vadis”, the VDMA Printing and Paper Technology Association asks its member companies about their plans, solutions, and challenges on the road towards a circular bioeconomy. What can the industry sector contribute? Dr. Michael Weiss, Vice President New Business & Research at Voith, Heidenheim, talks about sustainable use of resources, the desire for stringent, reliable framework conditions, and new technologies. In conversation with Dr.Michael Weiss Pictures: Voith Bioeconomy – Quo vadis Increasing sustainability and efficiency of papermaking process Professional Papermaking 1.2022 23 INTERVIEW

be to pave the way for the further expansion of renewable energies. In this context, the necessary infrastructure, such as transport networks and storage systems, must also be promoted. In addition, the development and market introduction of low-carbon-emission production technologies should be supported and accelerated. What role does the topic of sustainable use of resources play in your research and development? The trend toward sustainable papermaking, and in particular the decarbonization of the papermaking process, already play a very important role in Voith’s research and development and are a central pillar of Voith’s strategy. Important focus areas here include reducing energy and water consumption in the papermaking process, further increasing the recycling rate, and improving raw material yield and quality. In addition, new fields of application for the raw material paper and cellulose fibers are being developed, for example as a sustainable substitute for mineral oil-based packaging solutions. Other important criteria and development goals are the further expansion of digitalization and the continuous improvement of the cost and resource efficiency of our machinery and equipment portfolio. Voith and Meri presented AquaLine Zero, a forward-looking water management concept with a completely closed water cycle. All water used in paper production is cleaned by an in-house purification system with state-of-the-art treatment technology and is fed back into production as recycled water in a resource-saving manner. This means that no process water is discharged from the paper mill and the actual fresh water consumption is reduced to only about 1.5 liters per kilogram of paper produced. Decarbonisation will pose major challenges for paper producers and other industries in the coming years and decades. The Green Deal adopted by the EU envisages carbon neutrality in the EU by 2050, and greenhouse gas emissions are to be reduced by 55 percent by 2030, measured against 1990 emission levels. To achieve the ambitious carbon reduction targets in the paper industry, disruptive concepts and novel approaches are needed in addition to the continuous development of existing technologies. The development and implementation of these concepts and technologies is part of our sustainability strategy at Voith. Are the challenges in your industry different regionally or the same globally? Sustainability, decarbonization, and the associated changes in our industry are global developments. For example, the Chinese government has also declared its goal of being carbon neutral by 2060, and the USA, under new political leadership, has rejoined the Paris climate agreement. However, these developments towards a sustainable bioeconomy are most advanced in Europe. The leading industrial nations want to achieve climate neutrality by the middle of the century. Do we need political support for the bioeconomy? If so, what do you specifically expect from policymakers? It is the task of politicians to create clear framework conditions and make reliable decisions in order to provide investment security for all players in the markets and along the value chain. This is necessary in order to successfully implement the transformation towards a circular bioeconomy and, at the same time, to further increase the profitability and competitiveness of paper producers. Another important point will ABOUT! VDMA The VDMA Printing and Paper Technology Association is the voice of around 170 European manufacturers of equipment and systems for printing and print processing, paper production and processing, and auxiliary materials and equipment. It thus represents around 90 percent of the industry. The trade association offers its members services, for example on topics such as trade fairs, public relations, technology and research. Paper quality test in Bhigwan, India Professional Papermaking 1.2022 24 INTERVIEW