Verantwortung Vertrauen Partnerschaft D i e U n t e r n e h m e n d e r H e l l e n b r a n d G m b H consulting project planning design calculation development manufacture assembly installation start-up maintenance stock preparation and reject handling new systems and optimisations special solutions and special mechanical engineering spare andwearpartsforthepaperandboardindustry 1
Verantwortung Vertrauen Partnerschaft D i e U n t e r n e h m e n d e r H e l l e n b r a n d G m b H 1996 foundingofworkshopin Lambrecht / Pfalz forrevisions, manufacture, service for: paper mills, automotive suppliers, pump manufacturers 2016 30+ qualified staff, modern machinery 1994 founding of engineering office for efficient individualised stock preparation solutions 2004 2011 cooperation with Metso Paper: GW delivers superiour pulper cleaning systems for Metso projects 2013 change of ownership to Michael Hellenbrand 1890 foundingof theunterweser Reederei (shippingcompany/ towing boats) in Bremen: focus on ship engines 1970s official manufacturing and service partner for Voith: 1) Voith-Schneider propellers (patented ship engines) and 2) paper industry for Northern Germany 2015 change of ownership to Michael Hellenbrand 2016 30+ qualified staff, modern machinery Your Advantages: combined knowhow and experience from 3 specialised companies 1 contact for consulting, planning, design, manufacture, start-up and service 2
Consulting + Engineering efficient stock preparations since 1994 Efficient Stock Preparation Onsite Layout optimisation Flow sheet Motor data ROI 3D simulations CAD planning Pump data targeted holistic Made in Germany energy Pipe dimensions Start-up Control circuits 3
GW Pulper Cleaning efficient pulping and cleaning continuous production high consistency up to 4-6 % in pulper low energy consumption some plants run with max. 12 kwh/t fibre loss in reject below 8 % flakes in pulper accept below 6 % pulper volume circulation 120-130 x per day optimiseddesign ofmachineryforlife-times + reduced maintenance requirements Pulper Reject Pump Junkscreen Dewatering Drum 4
GW Pulper Cleaning Solidus Solutions Coevorden Reduction of Fibre Loss Production approx. 300 tpd with continuous pulper cleaning System before with pump and reject drum. New GW system start-up first weeks of 2017: GW Reject Pump 400/400 GW Junkscreen 17 Results: Total reject (pulper cleaning + coarse screening) in relation to used raw material: Before upgrade ø 8,3 % After upgrade < ø 7 % Additional benefit with a pulper screen plate with smaller perforations: Energy savings in coarse screening decreased immediately by over 7 % Less wearing on the coarse screening equipment. Customer confirms in January 2018 an ROI 12 months. Example calculation: Reduction of reject/saving fibresby 1 % at a production of 200 tpd => 2 tons less fibreslost and 2 tons less reject disposal to pay for => estimated prices 130 EUR/ton of OCC, 70 EUR/ton reject disposal => 400 EUR/day. With 350 operation days in a year => 350 x 400 = 140.000 EUR/year. The better pulper cleaning results and cleaning capacity allow for an increased in production capacity as well as the use of worse quality raw materials containing a higher percentage of reject. 5
GW Pulper Cleaning Metsä Tissue Raubach Capacity Increase Discontinuous Pulper Cleaning System before GW optimisation: Pulper 18m³, pulper emptying pump, screening machine, screw conveyor for reject transport Pulper charges: Production: 2.9-3.8 tons waste paper, colouredfilesand folders, includingleitz-folders and own broke(cleaning towels) 102-105 tpd Stock consistency: dilutedto4.5 % forpump and screen (fromø 18 % in the pulper) Challenges: capacity increase and reduction of times with an overflowing conveyor GW System Optimisation for discontinuous pulper cleaning system: GW Reject Pump 400/400 GW Junkscreen 30 EL GW Dewatering Drum CON 3 start-up in September 2017 since then operation without disturbances Results: Productioncapacityincreaseto 115 tpd (emptying of pulper 8 minutes instead of 12) The second PM partly uses now OCC instead of virgin fibre due to the higher capacity of the OCC stock preparation Stock consistency diluted to 6.5 % forreject Pump + Junkscreen Efficient separation of usable fibers and reject in the Junkscreen Reduced expenses: fibresnot lost in reject save raw material and reject disposal costs clean and saleable metal reject: The clean reject at the dewatering drum has less weight and the Junkscreen-heavy-reject is fibre free. The Junkscreen has a supporting pulping effect that helps recycle more fibres from the used raw materials. Cleaner working conditions in the pulper cleaning area no more overflowing of equipment. 6
GW Pulpers for your efficient pulping -energy efficient high quality pulping for waste paper, virgin fibre and special raw materials - optimised design and results individual rotor design depending on raw material + function = consistency 4-6 % = fast submersion of raw material = fast separation / pulping = low energy consumption (7 to 12 kwh/t) sizes from 6 to 80 m³ optimised open screen area if applicable heavy reject trap(s) if applicable 7
GW Raggers for your continuous production -removes safely wires, plastics continuously from pulpersoptimised design and results driven top pressure wheel with exchangeable wear teeth = more traction on the tail optional measuring device monitoring forces below pulper surface optional automated control for in-time reaction = reduced accident hazard 8
GW Reject Pump for your efficient pulper cleaning the heart of the pulper cleaning - resistant high performance pump to movestock frompulpertoscreensoptimised design and results centeredinlet DN400 centeredoutlet DN400 on top optimisedrotor* reduced rag building = reduced plugging* reduced energy consumption (average 20-30 kw)* frequency controlled all housingsduplexand 1.4571/1.4301 wear protection duplex/duplex coating *articleaboutrotorresults including Papierfabrik Vreden, Solidus Solutions Bad Nieuweschans 9
GW Junkscreen for your efficient pulper cleaning formaintenance/ revisions: 1 man canopen door easily -rejectremoval light andheavy - optimised design and results centered inlet centered light reject outlet on top heavy rejecttrapat thebottom optimised rotor optional: bearingavailablealso adjustable from the outside 10 all housings duplex and 1.4571/1.4301 - door covered with Duplex inside 10
GW Dewatering Drum for your efficient pulper cleaning - dewaters the light reject removed withthegw Junkscreen - optimised design and results conicalscreen stainless steel wheels with constant lubrication showerpipe water tank with level transmitter collected water is used for washing the GW reject pump 11 11
GW Coarse Screening efficient screening and removal continuous production with only 1 pump since over 30 years high consistency up to 4 % low energy consumption 1.5 % less fibreloss in reject than market competitors saving long and strong fibres! efficient removal of light and heavy reject efficient wear protection for high life-times 12
GW Vortexdrives for your efficient coarse screening -removes light and heavy reject - optimised design and results centered inlet, reject outlet on top door opens easily optimisedrotor= lowenergy consumption + efficient separation of rejects all housings duplex and 1.4571/1.4301 -door covered with Duplex inside consistencyupto4 % optional: bearingavailablealso adjustable from the outside 13
GW heavy reject cleaners (SSLs) for your efficient coarse screening -efficient removal of heavy reject between GW Vortexdrives and GW Lastvortexoptimised design and results consideration of centrifugal forces, optimised times for removal and reject thickening pressure decrease between Vortexdrives backwashing insert increases life-time various wear resistant coatings available (e.g. aluminium oxide, rubber) 4 sizes for correct throughput 14 14
GW Lastvortex S + Z for your efficient coarse screening Last step in the GW coarse screening: Saving your long and strong fibres!! optimised design and results with separate horizontal and vertical screen intensified opening and screening reject thickening for better handling afterwards optimised separate speed control optimised separate control of stock consistency in both machines pressure decreasing side-effect stock consistency up to 4 % all housings duplex and 1.4571/1.4301 -door covered with Duplex inside 15
Extract of References systems and optimisations Solidus Solutions (former Smurfit Kappa): 2016/17 new pulper cleaning for mill Coevorden = total reject amount reduced from8 to6 %; 2011 newpulper cleaningformillbad Nieuweschans = 1) highercapacityand2) efficiency 3) savingenergyin the coarse screening. CURRENT PROJECT coarse screening upgrade spring 2018 MetsäTissueRaubach: 2017 newpulper cleaningsystemwithreject Pump andjunkscreen 30 EL = moreproduction capacity, better metal separation, less fibre loss in reject, reduced energy consumption in coarse screening Papier-und Kartonfabrik Varel: 2016 newreject Pump, Junkscreen 25 forpm5, 2010 : 2 Reject Pumps, 2 Junkscreen 25, 3 Vortexdrives, 4 SSLs customer since 1996 UPM Nordland Papier: 2017 newrotorforbrokepulper energysavings10 % (65 to53 kw) Eska, Netherlands: 2016 2 GW pulper rotorsfor2 ST5 pulpers betterpulpingresultsandlessenergyconsumption Papierfabrik Palm, Wörth: 2016 consultingon capacityincreaseofstock preparationlinesfromgw deliveryof4 linesin 2005 Aviretta GmbH: 2014/15 modification and new installation of the stock preparation for changing from graphic paper to packaging papers, change of HC pulper to MC pulper Model AG, Switzerland: 2016 RejectPump fortetrapakline, 2003: SP320 pulper, RejectPump, Junkscreen Kartonfabrik Porstendorf: Last Vortex S saving long and strong fibres SmurfitKappa Argentina: ST5 newrotor= energysaving25 % + less cutting ofplastics= lesswearingin subsequent equipment Filter manufacturer: ST4 newrotor= energysaving15 % + 33 % time savingswhenpulpingspecialrawmaterial StoraEnsoMaxau: brokepulper AK26 newrotorsandscreens = 20 % energysaving+ capacityincrease ofabout40 % 16
Hellenbrand Maschinenbau for your efficient production Mechanical Engineering and Projecting tailor-made solutions forthepaperand board production 17
Development + Resources for your efficient production 1996 founding of the mechanical workshop 2016 30+ qualifiedand skilledemployees, modern manufacturing equipment Focus of our works: stock preparation and reject handling special machine engineering and projecting higher life-time of wear parts improved process safety and machine reliability 18
Stock Preparation machines, wear parts, repairs difficult-to-get-by spare parts screening equipment hardened screens screen boxes bearings housings roll carriages 19
Stock Preparation machines, wear parts, repairs propellers rotors refiners deflakers pumps cleaners 20
RejectHandling shredding, pressing, separating, transport efficient and reliable shredding* and drying of reject separation of water and reject conveyer belts and screw conveyors optimised machines and wear parts for hightes life-times and least maintenance requirements *Shredders also available for other operations just contact us with your inquiry. 21
RejectShreddingwith Hellenbrand Shredders Design according to Your Needs! Drives hydraulic or electric high quality materials proven hardening process 2 and 3 shaftshredders(upto220 tpd reject with one shredder) no re-tensioning after start-up no play no corrosion in bearing areas blade size choosable some references new/optimised/service: Leipa Schwedt (opt.) blade life-time: > 16 months (before: 4 months max.) PK Varel newshredder ProPapier PM2 new+optimised shredder+service UPM Rhein Papier spare parts+ service Papierfabrik Palm spare parts + service 22
RejectShreddingwith Hellenbrand Shredders Your shredder needs high quality service in our workshop? Inquire for spare shredder to not lose production time! 23
RejectShredding spare andwearparts on stock exact,accuratefit ofall pieces = next tonoplay corrosion protection with grease lubrication 24
RejectPresses new, optimisation, parts, service reliable drying of rejects highest life-time and drying degree guaranteed inquire fora rentalmachineto minimise production loss due to the service time highest life-times of parts and optimised frames all commonwear andspare parts are on stock! You know this? Talktous! References include millsfromupm, Smurfit Kappa, DSSmith, Mayr- Melnhof, Raubling Papier. 25
RejectPresses manufacture, optimisation and repair machines screws housings frames bearings 26
RejectPresses screen shells new screen and dewatering drums on stock completerepairofyour old screen shells if economically sensible barsforshells individual perforationanddesign upon request 27
SludgeandReject transport and separation design according to your needs drives hydraulic or electric horizontal, vertical, inclined 28
SludgeandReject transport and separation Design according to your needs! drives hydraulic or electric drive on top efficient separation + removal 29
Heavy Reject Separator (SST) PROJECT Papierfabrik Tillmann 2016/7 Design and Manufacturing Sedimator 2 and 3 : Heavy reject separation works very well low water collection. Non-Standard Solution -accordingto customerdesirean SST with a larger screwdiameterwas designedand successfullyinstalled. We offer our customers: calculation, design and manufacture according to needs and customer wishes installation and start-up drive installed on top efficientseparationand removalof heavy reject 30
Projects inclined conveyor Project Scope: On-site check new layout design + engineering manufacture installation start-up 31
Projects: Scratch-Conveyor solids removal from clearing basin Project Scope: consulting and determination of aims with customer calculation and design manufacturing drawings manufacture of machine and control unit installation and start-up After successfull start-up in August 2016 our customer PK Varel ordered 2 more scratch conveyors in November 2016. 32
Projects: rebuilt frames of size press Project Scope: deinstallation measurement drawings manufacture installation 33
Projects optimisation pulper bearing housing before Before: many shutdowns due to broken welding seems and broken pulleys Project Scope: consulting new calculation and design of bearing and housing engineering manufacture mounting 34
Projects optimisation pulper bearing housing manufacturing and finishing after 35
Projects rebuilt press section Project Scope: deinstallation measurement drawings manufacture installation 36
Shutdown+ RepairService revisions, repairs, new installations mounting and deinstallation in all areasofyour plant! ex-changes ofrolls and all other parts on your machines. repairs and maintenance 37
Shutdown+ RepairService revisions, repairs, new installations machine revisions pump service* overhauling + repairofwire-and felt guides* *in cooperation withupag / Unterweser Papiertechnik GmbH 38
Manufacturing Examples various pieces 39
MechanicalEngineering andmaintenance since 1890 Maintenance forthepaperand board production stock preparation gear units rolls pumps paper machines Quality from Tradition since 1890 40
Paper Industryand Shipengines Workshop in Bremen since1890: manufacture and maintenance of engines/ gears Voith Schneider Propeller equipment for stock preparation and reject handling wireandfeltguides vacuum pumps 41
Paper : wire- andfelt-guides complete qualified repair and service new and overhauled guides upon request deinstallation and reinstallation appraisals all common types and sizes note: UPAG was manufacturing and service partner for Voith References include: MelittaGmbH, Minden; DelkeskampVerpackungswerke GmbH; PK Varel; Hamburger Rieger; Smurfit Kappa Zülpich Papier GmbH, Feldmuehle Uetersen 42
Paper andboard: stock preparation repairs and manufacture: Rotors, screenplates, housings, bearings, coatings, etc. on-site revisions 43
Paper + Ships: Vacuum-/ Pumps qualified repairs and maintenance on-site revisions and exchange of parts deinstallation and installation vacuum-, Hibon-, headbox, mixingand multi-stage pumps Eachpump isputon ourown testingstand before it leaves our workshop! References include: Papierwerke Klingele, Weener; PK Varel; Mitsubishi HiTec Paper Europe, Bielefeld & Flensburg; Feldmuehle Uetersen; Melitta Spezialpapier; Smurfit Kappa C.D. Haupt, Diemelstadt-Wrexen, Sprick Papier, Smurfit Kappa Zülpich, Julius Schulte Düsseldorf 44
Paper + Ships: Vacuum-/ Pumps qualified repairs and maintenance on-site revisions and exchange of parts deinstallation and installation vacuum-, Hibon-, headbox, mixingand multi-stage pumps Eachpump isputon ourown testingstand before it leaves our workshop! References include: Papierwerke Klingele, Weener; PK Varel; Mitsubishi HiTec Paper Europe, Bielefeld & Flensburg; Feldmuehle Uetersen; Melitta Spezialpapier; Smurfit Kappa C.D. Haupt, Diemelstadt-Wrexen, Sprick Papier, Smurfit Kappa Zülpich, Julius Schulte Düsseldorf 45
Paper andboard: stock preparation machinery + maintenance: pulper, horizontal and vertical screens, pump, cleaners, refiners, deflakers 46
RevisionsandRepair of Axial Blowers Disassembly appraisal and recommendations renewal of bearing If required or ordered: separate parts sandblasted and coated with twocomponent coat 47
Shipwork shop: maintenance all repairedshipenginesareputon ourowntestingstand before dispatch! Ruderkoker 48
Paper + Ships: shutdown maintenance Benefit from our praxis experienced staff! De- and installation in areas ofyour plant! roll changes, exchange of slip ring sealings, pulper and screen parts, support frames and other plant parts 49
Verantwortung Vertrauen Partnerschaft D i e U n t e r n e h m e n d e r H e l l e n b r a n d G m b H 50
Verantwortung Vertrauen Partnerschaft D i e U n t e r n e h m e n d e r H e l l e n b r a n d G m b H 3D Installation Planning Fractionation 51
Verantwortung Vertrauen Partnerschaft D i e U n t e r n e h m e n d e r H e l l e n b r a n d G m b H Hellenbrand Maschinenbau GmbH Beerentalstr. 3 67466 Lambrecht Germany Telefon: +49 6325 98841-0 Telefax: +49 6325 98841-49 E-Mail: info@hellenbrand-gmbh.de GW Fasertechnik GmbH Beerentalstr. 3 67466 Lambrecht Germany Unterweser Papiertechnik GmbH Leerkämpe 4 28259 Bremen Germany Telefon: +49 421 5200 3-0 Telefax: +49 421 5200 3-50 E-Mail: info@upag-papiertechnik.de The Hellenbrand Group offers you efficient stock preparation and reject removal and handling. You get one of the most efficient systems for pulping, cleaning and reject removal available on the market. Check this link for an animated video of the main features and benefits you get: http://movie.hellenbrand-gmbh.de/english/. Telefon: +49 6325 98841-60 Telefax: +49 6325 98841-69 E-Mail: info@gw-fasertechnik.de 52