Cascades Bear Island PM 1 grade conversion rebuild

The Valmet supplied grade conversion rebuild consisted of two Valmet Disc Refiner DD6000 units, broke collection, Valmet Stock Mixing MD technology, a new OptiFlo Gap headbox, improvements and modifications from forming section to drying section, process air systems rebuild, a new OptiSizer Film size press and Valmet Starch Cooking ZE system, reel rebuild, parent roll handling rebuild, and a new OptiWin Drum two-drum base winder.

The process technology supply was supported with Performance Agreement that included:

• Both local onsite and global remote Valmet expert support to improve process reliability and performance
• Advanced monitoring and prediction applications to optimize performance with data and intelligent software
• Paper Machine Clothing with related services
• Consumables and spare parts
• Roll agreement with related services and maintenance

The automation scope included Process Control System (DCS), Quality Measurement System (QMS), Runnability and Condition Monitoring System, and Web Monitoring System.

In the containerboard business, achieving high compression strength is crucial to prevent boxes from being crushed. Meeting stringent strength targets for both medium and linerboard is essentially important. Within just two weeks, quality targets for corrugating medium were already met, and shortly after, the targets for linerboard were achieved.
 
To remain competitive, producing top-quality products that meet strength property targets is a necessity. In addition to that, the ultimate test is how the sheets perform in the customers’ facilities, especially with the increasing investments in high-speed corrugators. As these machines operate faster, they require a very stable product to ensure smooth unwinding. Therefore, reliability and stability in the end products are paramount to meet customers’ speed targets on the corrugators. Cascades customers appreciate the stability of their sheets in both cross-direction and machine direction.

The mill is over four times lower in water consumption and more than twice as efficient in energy consumption as their North American peers. This efficiency was a key design goal for the Bear Island Mill, and within a few months of start-up, they had already met their water consumption targets.