Optimization of a paper machine for fine papers

This lecture is not a detailed representation of latest technologies. It rather tries to show some aspects of an improvement process which includes the product in his market environment the paper machine in the field of it's competitors as well as the different technologies in respect to various existing production methods. Paper Machine PM 2 of M-real Zanders GmbH produces coating base paper mainly for the market of double-side coated papers since 1969. In case one intends to remain competitive with such an "old Lady" of 320 m machine width, it is necessary to permanently lower costs and improve the quality by specialization, innovation and investment. Particularly the balancing act between cost reduction and quality improvement was excellently achieved at the PM 2 by means of investments in automation, a dilution water cross-section regulation and a new top former. In addition the product range was moved towards the direction of higher basis weights in order to use synergies of specialization. Furthermore the productivity was increased by bypassing the size press and simultaneous rearrangement of the wet-end system of chemical additives. This improved the quality properties without reaching the limits of the customers. The increased recipe costs got over-compensated by energy cost savings. The lecture deals with some real life examples of problems that have arisen from process optimization and finishes with a resume about importance of taking the full scope system into account.