Liansheng Pulp and Paper: big success with PM 1 carton board and PM 3 high-grade fine paper lines
Feb 27, 2024
Living up to expectations, Liansheng’s carton board and high-grade fine paper production lines have been recognized as a success not only by Liansheng, but also by their customers.
Valmet’s cooperation with Liansheng has continued to deepen by the start-up of carton board production line PM 1 and high-grade fine paper production line PM 3 in May 2023 in their Zhangpu site. This is a continuation to a long collaboration between the companies, preceded by prior deliveries of corrugated paper line PM 3 in Changtai site and by PM 5, PM 6 and PM 10 corrugated paper and liner board lines in the Longhai site. Extensive and reliable technology by Valmet, including maintenance services, automation systems, flow control and Industrial Internet applications, enables Liansheng to transition into new markets with the deliveries of PM 1 and PM 3.
“We’ve always recognized Valmet’s innovative spirit. The production lines they have supplied have a minor impact on the environment and low operating costs, and our user experience has been excellent. So, when we were looking for partners for carton board, high-grade fine paper, bleached-chemi-thermo-mechanical pulp (BCTMP) and tissue paper at the Zhangpu base, Valmet’s competent global expert network as well as continuous innovation, made it by far the best choice”, concludes Xue Rongjun, General Manager of Liansheng Pulp and Paper (Zhangzhou) Co., Ltd.
| Huang Ju, Deputy General Manager of Liansheng Pulp and Paper (Zhangzhou) Co., Ltd., proudly states that the cooperation between Liansheng and Valmet at the Zhangpu base has achieved industry-recognized success, which is a significant achievement in the development of Liansheng. “It’s been a big success, no question! Not only do I think it’s successful, but everyone at Liansheng and our customers think that the project has been very successful. It was not expected that Liansheng would be able to produce qualified products so quickly and even to exceed customer expectations of entering the market.” |  |
Excellent start-up and fast market acceptance
In May 2023 the carton board production line PM 1 was operational half a month ahead of schedule. The machine was successfully started up on May 1, and sellable A-grade carton board was produced three days later. Ten days later, the product was placed on the market, and customers highly appreciated the paper’s bulk and flatness. The speed at which the production and quality of the carton board was achieved exceeded downstream customers’ expectations.
A month after the PM 1 start-up the high-grade fine paper production line PM 3 was also successfully started up. Sizing was successful on the first day and all the produced fine paper passed quality inspections very early on. Customers are very satisfied with the uniformity, smoothness, and even two-sidedness. At the same time, PM 3’s start-up curve is exemplary: The average speed in October 2023 was 1,650 m/min, with a production of 50,100 tonnes, and the current speed (as of November 2023) has reached 1,708 m/min.
"The quality of our fine paper is the biggest advantage. Since the early stage of the start-up, customers were very satisfied with our uniformity, even two-sidedness and smoothness, which are the best features of the base paper. The formation in both the high brightness paper and the xerographic copy paper is also excellent for the industry.”
Comprehensive scope and reliable technology ensure high-quality carton board and fine paper production
Today, on PM 1 carton board and PM 3 fine paper production lines, Valmet’s production, automation and service engineers and Liansheng workers each play their roles and cooperate to ensure that the production and quality of each paper roll meet the standards.
“Looking at PM 1 carton board line, we can achieve a bulk of over 1.63 cm3/g, which gives us a big advantage. Customer feedback is also very positive about our flatness.” Huang Ju, Deputy General Manager of Liansheng Pulp and Paper (Zhangzhou) Co., Ltd.
When it comes to the technical highlight that contributes most to the quality of carton board, Huang Ju praises Valmet’s design of the three nip OptiPress Linear press section, which not only highlights the advantage of high bulk but also ensures flatness, without damaging the strength of the base paper. Through process adjustments in the forming and press sections the flatness and stability of the paper products have further improved. The additional washing of the BCTMP not only raises the pulp’s cleanliness to new heights but also makes a big contribution to paper products’ uniformity and whiteness.
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"The quality of our fine paper is the biggest advantage. Since the early stage of the start-up, customers were very satisfied with our uniformity, even two-sidedness and smoothness. The two-sided evenness’s and the uniformity of the base paper are the best features. The formation in both the high brightness paper and the xerographic copy paper is also excellent for the industry.” Zheng Fenglin, Senior Vice General Manager of Fine Paper, Liansheng Pulp and Paper (Zhangzhou) Co., Ltd. |
Adding mechanical pulp to fine paper is an important way to improve bulk. Zheng Fenglin is very satisfied with the papermaking effect of adding a high proportion of mechanical pulp: “The uniformity of our base paper is excellent because we use BCTMP. The amount of our base paper BCTMP has reached new heights in the industry, contributing greatly to our profitability.”
Huang Ju believes the significant advantage of Valmet’s ability to deliver the technology for the entire production process is the key to maintaining the quality on stable level for both the carton board and fine paper lines.
“Having one single technology supplier to the entire production process significantly enhances the staff’s ability to work, reduces their need to adapt and increases operational stability. Second, identical process spare parts reduce inventory and are more cost-effective. Most importantly, Valmet’s equipment, from BCTMP to pulping to paper machines, is very stable, ensuring the stability of paper quality.”
Zheng Fenglin strongly agrees: “The processing of raw materials, automated approach flow, paper machines, winding, packaging, and other equipment are all on the same automation platform, which benefits resource sharing and optimization. The control of such a wide paper machine would be a challenge for any manufacturer, but when the equipment and automation systems are from the same supplier, it’s easy to optimize, balance and coordinate. This contributes to PM 3’s good performance.”
Market leading, proven technology effectively reduces energy consumption of carton board production line
It is well known that the cost effectiveness of paper production has a significant impact on the company's profitability. In addition to the raw material cost, energy consumption is also crucial. Li Guowei, Senior Manager PM 1 at Liansheng Pulp and Paper, believes Valmet’s OptiCoat Jet coating stations, Valmet Conical Refiner Conflo refiners and OptiAir high-humidity hood have effectively reduced the production line’s energy consumption:
| “First, Valmet’s coater and coating air dryers have high drying efficiency, with natural gas consumption per tonne of paper at 5.5 to 6 cubic meters. When the design capacity is achieved, the single consumption of natural gas can be reduced to five cubic meters. Second, the power consumption and refining result indicate that Valmet Conical Refiner Conflo refiners are very stable in operation and ensuring long segment lifetime. In addition, the dryer section ventilation operates efficiently. Steam consumption is reduced by utilizing condensation water and air to air heat exchange. Hood air balance combined with zero-level adjustment, ensures stable runnability and better energy efficiency.” |  |
Huang Ju summarizes the carton board production line’s energy consumption: “Valmet’s coater offers high drying efficiency, and the carton board production line’s natural gas consumption is very low. Thanks to the cleanliness of the BCTMP, the advanced technology of Valmet’s equipment and Liansheng’s process design in the wet end section, the consumption of clean water is 4 m³/tonne of paper, which is relatively low for the industry. PM 1’s capacity has still not been fully utilized, but our overall electricity, water and natural gas consumption is excellent.”
Reliable equipment ensures robust operation on the carton board production line
Valmet’s reliable equipment provides strong support for the stable operation of PM 1 carton board production line. Huang Ju says Valmet Doctor Holder Blow has reduced the time for paper breakage and speeded up the tail threading, which has been reduced from the original one hour to 35 minutes since the start-up. Li Guowei mentions that the ropeless tail threading system in double-fabric groups ensures stable operation and production efficiency. The zoning of OptiCalender Hard and OptiCalender Soft calendering has expanded Liansheng’s operating possibility for accurate thickness profiling between base paper and finished paper.
“I’m very satisfied with the configuration and operational stability of each piece of equipment on Valmet’s carton board production line, and I believe a speed of 1,300 won’t be a problem.” Li Guowei, Senior Manager PM 1 at Liansheng Pulp and Paper (Zhangzhou) Co., Ltd.
“Since the start-up, except for routine maintenance, there’s been no major work due to equipment damage or vibration on the paper machine equipment. This long period of normal operation, including the continuous increase in speed, proves again and again just how good Valmet’s equipment is!”
High-grade fine paper production sets a new benchmark
October 2023 set a benchmark for Liansheng Pulp and Paper’s fine paper production line. The production rate for grade A products for the entire month is 99 percent, the paper yield rate is 95 percent, equipment operation efficiency is 97 percent, output is 50,100 tonnes, and average speed is 1,650 m/min. Water consumption is 5 m³/tonne of paper, and electricity consumption is 550 kWh, which is also the best level in terms of water and electricity. Zheng Fenglin is very satisfied with this performance: “There were several highlights with PM 3 in October, whether it was the efficiency of raw material use, product quality or the safety of the production line.”
Shao Qichao, the Senior Manager PM 3 at Liansheng Pulp and Paper, greatly values Valmet’s technology. He points out six highlights from the Valmet technologies. First, the OptiAir high-humidity hood offers significant energy-saving advantages for heat recovery. PM 3’s steam consumption is currently 1.3 tonnes/tonne of paper. Second, efficient wet end ventilation prevents pulp from entering the paper surface and causing paper breaks. Third, Valmet’s conical refiners´ energy consumption is lower and fiber treatment improved compared to disc refiners. Fourth, the OptiSizer Film sizing technology features controllable, uniform sizing. Fifth, the smoothness of the OptiCalender Hard calender is good, and the roll maintenance costs are low. Sixth, the OptiReel Linear with center-driven reel can ensure consistent pressure in the paper width contact area, which is very helpful for the quality of the paper, especially during winding.
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“Since end of September 2023, PM 3 has been the best performing of all the machines. In October, it achieved its best results, with an operational efficiency of 97 percent at the standard speed, and a production of 50,000 tonnes, exceeding the designed capacity. We are indeed very satisfied!” Shao Qichao, the Senior Manager PM 3 at Liansheng Pulp and Paper |
Co-operation is the key
For Liansheng and Valmet, launching two production lines at the same time was a huge challenge. Whether it’s equipment supply, factory construction, staffing or equipment installation, Zheng Fenglin recalls many emotions from the past two years:
“With the domestic and international environment, assembly, and logistics, this project had challenges, but neither Valmet nor Liansheng’s project department gave up. We had daily meetings to track progress and arrange work according to the installation and commissioning plan. Although we’ve encountered many difficulties, they haven’t hindered our cooperation.”
Liu Jianwei strongly agrees: “Whether it was during the initial communication or the installation phase, whatever problems arose, Valmet always took the problem-solving approach, always considering the customer and was always committed to solving the problem first. They’ve been diligent from start to finish, ensuring our project’s smooth start-up. The Liansheng’s carton board project is widely recognized as successful within the industry. We even produced qualified products within the first ten days.”
“Our overall cooperation has gone very well: From the sales and contract execution phases to the installation and commissioning phases, the collaboration has been very enjoyable!” Huang Ju emphasizes again.
Co-operation continues to deepen
With the production of various types of paper at Liansheng’s Zhangpu base, the company has ushered in a new era of product diversification, further enhancing their corporate image and product competitiveness. With the commissioning of the first phase of the Zhangpu project and the start of the second phase, Liansheng will significantly reduce transportation and raw material costs due to its regional advantages. The commissioning of the second phase of the pulp project and the strong complementary product combination also makes the company’s integrated “forest-pulp-paper” products more competitive.
Liansheng recently placed repeat orders with Valmet for coated board making line (BM 2) with related automation systems, bleached chemi-thermo-mechanical pulp (BCTMP) technology and two small size tissue machines (TM 5 and TM 6). In addition, Valmet will supply four tissue machine headboxes for tissue machines TM 7, TM 8, TM 9 and TM 10 at the same site.
Commenting about the decision to choose Valmet again, Huang Ju says: “All the products that Valmet has provided us have exceeded our expectations – whether it’s BCTMP, fine paper, carton board or tissue paper production lines, everything’s reached the design output, cost, and quality requirements. Especially in terms of quality, the downstream users have given us very high evaluations, and market competitiveness is excellent, as are the maturity and stability of Valmet’s equipment. There have been no major equipment accidents from the start-up to now, and no major technical modifications in the process. This means we get the continuous and stable products we need.”
“We’ve highly valued Valmet over more than a decade of cooperation. From our operators at Liansheng to the company’s management and its highest decision-making level, we all think Valmet has proven technology and is very reliable. So Valmet will continue to be our preferred choice as the Zhangpu project’s second phase begins.”
Text: Silvia Xi, Elsa Sinjaga
Read more about the technologies Liansheng highlights in this article
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