Jun 16, 2006. /Lesprom Network/. Paper mill Papierfabrik am Neckar in Gemmrigheim (formerly Steinbeis Temming Papier) has been re-established as a new independent company. Coloured printing papers and uncoated as well as coated offset papers are produced from 100% recovered paper on two paper machines. The mill recently selected Voith to audit the stock preparation system with the aim of increasing production from 210 to 260 t/24 h whilst maintaining existing product quality. The project included the preparation of a stock-water balance, technology benchmarking, an analysis of the composition of the rejects as well as a process water system analysis. The actual plant conditions were evaluated and a balance survey carried out as basis for the capacity expansion. This included precisely defining the capacity of the existing machines and auxiliaries. A further aim of the analysis was to reduce rejects. The rejects amount in the individual subsystems was established and - an important factor - the usable fibre content assessed. Recommendations for optimized machine adjustments as well as ROI calculations for the installation of new process equipment were also undertaken. It could be shown that in spite of relatively small reject quantities, the ROI for reject treatment using metal separation and reject compacting would be only 14 months. The comprehensive technological data collected in this way was then compared with the paper mill’s own data to check stock reproducibility. Additional benchmarking was carried out with comparable plant data to obtain an overall assessment of technology. The work showed there was an obvious potential for improvement in sticky and dirt speck reduction. A further significant cost saving potential was identified in screening and flotation, amounting to approximately Euro 400 000 per year thanks to savings in raw material and disposal costs. By examining the process water systems specific fresh water and effluent data were established and the existing process water management evaluated. Following this extensive technological evaluation of the plant, Voith’s engineers then carried out a mechanical status analysis of the actual working components (rotors, screen baskets etc.) in the machines. The mechanical condition of these components has a decisive influence on process technology, in addition to the machine operating parameters. This is why Voith recommends an overall plant survey consisting of technological as well as mechanical status analyses of the equipment. Statement by Jaakko Tuomola, managing director of the re-established company: "We will increase our paper machine capacities, further improve our current product qualities and place new quality grades on the market. Those times when products containing recycled paper automatically stood for a lower quality are long gone thanks to today’s technology. Restructuring of small mills like ours needs intelligent, cost-conscious solutions to be able to reduce dirt and stickies down to a competitive level, whilst at the same time increasing production from 210 to 260 t/24 h. As I have had good experience working together with Voith in fibre technology projects, my decision to select Voith for carrying out a system analysis came naturally”, added Jaakko Tuomola. Voith offers tailor-made solutions for system analyses and optimization to suit market requirements. Depending on the objectives, the work can include evaluation of subsystems as well as of complete lines in stock preparation and approach flows right through to mill-wide evaluation of fresh, cooling and effluent water flows. Besides conventional stock and water balancing, Voith also undertakes balancing of thermal energy and COD as well as of stock components including contaminants. Over the past 10 years Voith has carried out more than 100 plant analyses in system technology for board and packaging papers as well as for graphic and sanitary paper grades. Voith Paper is a division of the Voith Group and one of the leading partners to the paper industry. More than one third of the world's paper production is produced on Voith Paper machines. Voith sets standards in paper technology, power transmission engineering, power generation and industrial services. Founded on January 1, 1867, it has a current workforce of approximately 30 000, sales of Euro 3.5 billion and over 200 locations worldwide, and is one of the largest family-owned enterprises in Europe.