By MARK WILLIAMSON
Reel density optimization systems installed on three of
Kondopoga’s machines have significantly reduced bottom waste
DOING WHAT THE CLIENTS ASK
or some time now, paper web quality measure- feedback measurement of nip loading nor precisely con-
ments have been automatically controlled within trolled arm movement. As a result, reeled-in density and
very exact and miniscule tolerances. For instance, tension is not usually uniform from the spool outward.
sheet caliper is often measured with one tenth of a mi- With this expected and chronic waste near the spool,
cron precision – less than 1% of the width of human hair. jumbo reels are built to a larger diameter purposely -
On the other hand, the macro-scale methods of building and not so precisely- to meet winder set requirements.
a well-structured parent reel to exact tolerances needed Normally, several centimeters of unusable paper on every
for the winders have been lagging behind somewhat, jumbo reel are sent to the pulper.
especially on older machines. Naturally, paper mills have been looking for more
Without precision diameter measurements, opera- precise and repeatable ways to measure and control the
tors have continued to use rough “measuring stick” reeling process to produce jumbo reels with a maximum
techniques. Moreover, uncertain and inexact pneumatic amount of usable paper built to the exact diameter and
controls of the primary and secondary arms have caused sheet length needed for the winders.
a considerable amount of waste paper that cannot be slit
and wound reliably because of uneven tension and sheet ADDING TO SALEABLE PRODUCTION
wrinkling. This reeling control problem is particularly
acute near the reel spool. The Kondopoga mill has found a practical solution to this
In many mills, such as the OAO Kondopoga news- common industry problem with the commissioning of
print mill in the Karelia region of Russia, chronic “bottom three automatic reel density optimization systems (ROS)
waste” or “left-on-spool” losses have been the most sig- made by Vishay Nobel of Karlskoga, Sweden, on PM 8, 9
nificant contributor to dry end shrinkage losses. Paper- and 10. Two more ROS projects are to be completed in
makers have been struggling to build an even reel with early 2009 on PM 4 and 7. With the continuous use of these
older reeling systems which use pneumatic controls that systems by the operators, the bottom waste on all three ma-
date back 20 or 30 years. In these older systems, there is no chines has been reduced significantly, adding to saleable
production. At the same time, reel snap-off breaks have
been reduced or eliminated and the consistency of winding
density and wound roll sheet area yield has been improved.
These results were accomplished without a major
reel rebuild. Instead, the primary and secondary arm
positioning and nip loading systems from were con-
The real-time progress