A discussion covers the leeway available to further develop the web-based paper machine. R. Vötsch (Sappi Gratkorn GmbH), W. Moser (active in Gratkorn and Obering, Austria in technical matters), and A. Gutjahr (Norske Skog Bruck GmbH). The topics include wishes and expectations; sorting structure and product quality; meaning of automation; control surface; standardization; field installation; complete integration of system families; care and maintenance; PM and automation; energy supply; the human factor; perfection in engineering; and new initiatives. The entire production process and availability of the paper machines are to be increased. The wish for higher production includes higher speeds because the development in screen width to about 10m seems to be the limit. At speeds of over 1,200 to 1,300 m/min only the gap former may be able to improve the sheet structure for wood-free coated paper. Large changes are to be expected in the coming years in process control. The goal is to make the highly complex processes surrounding paper making in the large and rapidly running machines more transparent and controllable. Standardization of software is to be desired. Today one can not unconditionally exchange software applications from one system to the other. With respect to standardization of software packages and software tools further progress is desired. With respect to maintenance of computers, outside computer service can be called upon or the paper plant can develop its own plant computer maintenance staff. Having its own computer maintenance staff would lead to short downtimes and good care of the installation in which the system engineers identify themselves with their facility. Planned shutdowns are the largest share of paper machine shutdowns. The sum of technically caused shutdowns is about 3%. Of this, about 2% are planned for repair and maintenance. Only about 1% is unplanned because of disturbances to the mechanics, electricity, or energy supply and of this, 67% are caused by electrical reasons including the automation system and 33% are caused mechanically. Today with 10 m width and up to 2,000 m/min for light weight coated papers, a cost effective limit has been reached. New drying technologies would by use of high temperature, infrared, and vacuum systems shorten the very long drying part and reduce the high investment and operating costs. This would involve closing cycles and lead to considerations of carbon dioxide emissions and compliance with the Kyoto protocol.
