Dongguan City Taichang Paper PM3: Partnering with Valmet to usher in a new era of efficient production

Zhu Jack, Product engineer, Roll Covers and Maintenance from Valmet (left) and Chen Lin, Production Supervisor from PM3, Dongguan City Taichang Paper Co.,LTD. (right)

Strategic solutions to customer challenges

On Dongguan City Taichang Paper’s PM3 production line, several issues have historically hindered efficient production. These challenges include the rapid wear of calender roll doctor blades, the decreased hardness of worn iron roll surfaces, and the frequent need for roll grinding. The roll doctor blades in particular wear out quickly and require replacement change every seven to 12 days. These frequent blade and roll changes increase downtime and maintenance costs and adversely affect production efficiency. The old age of the rolls, some up to 10 years old, has resulted in a loss of hardened roll surface layer from wear and grinding. This reduced roll surface hardness has negative impact on the quality of paper products. Meaning the calender rolls have a short grinding interval of approximately one a year, further escalating the company’s operating costs. In response to these challenges, Dongguan City Taichang Paper was actively seeking effective solutions.

Dongguan City Taichang Paper Co., LTD, PM3 calender

Leveraging its extensive industry experience and advanced technological capabilities, Valmet provided customized solutions for Dongguan City Taichang Paper. To address the issue of reduced roll surface cover hardness, Valmet recommended its Valmet Calender Roll Cover CO-S. This advanced hard coating effectively protects the roll surface, preventing wear, thereby keeping the iron roll hardness and extending the roll’s service life. As a result of adopting this technology, the rolls at Dongguan City Taichang Paper have been in use for more than 36 months, significantly reducing maintenance costs.

PM3 calendering roll after coating with Valmet Calender Roll Cover CO-S at Dongguan City Taichang Paper.  

The cover surface’s increased hardness has resulted in a smoother roll surface, which has also significantly reduced the wear on the doctor blades, with the replacement cycle for the carbon fiber doctor blades now exceeding a month. This strong decrease in the frequency of blade changes has reduced PM3 downtime and has led to a marked improvement in production efficiency.

"Utilizing Valmet Calender Roll Cover CO-S has resulted in the significant enhancement of the calender rolls’ wear resistance, extending service life to three years. This advance has resulted in substantial savings in roll replacement and maintenance costs. Additionally, the lifespan of our doctor blades has increased from 15 days to 1.0 to 1.5 months, further reducing operating costs. Moreover, the improvement in paper smoothness has bolstered our market competitiveness. We find Valmet's product quality and service very reliable and trustworthy.” Chen Lin, Production Supervisor, Dongguan City Taichang Paper Co., LTD

Jointly driving innovative advances in the paper industry

By integrating Valmet’s cutting-edge technology, Dongguan City Taichang Paper’s PM3 has achieved remarkable advances. The doctor replacement cycle has been significantly extended, reducing downtime and enhancing production efficiency. The rolls’ service life has also been greatly prolonged, minimizing the need for frequent grinding and replacement. Concurrently, the smoothness of the paper surface has markedly improved, meeting the market’s demand for premium-quality paper products.

The collaboration between Dongguan City Taichang Paper and Valmet marks another innovative step toward production optimization. These accomplishments have not only bolstered the competitiveness of Dongguan City Taichang Paper but have led to significant improvements in both production efficiency and paper quality. Looking ahead, both parties are committed to deepening their cooperation and jointly driving innovative advances in the paper industry.

Text: Jack Zhu, Product engineer, Roll Covers and Maintenance, Valmet