Varaoke International Oy

https://varaoke.eu/products/paper-machines/paper-machine-producing-200-tpd-deckle-of-2500mm/

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Varaoke International Oy
Business ID: 0925191-4
Kullervonkatu 20 B 112
33500 TAMPERE
Tel: +358 10 292 2090

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Harri Aikio
Kullervonkatu 20 B 112
33500 TAMPERE

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Sulje [x]

Paper Machine. Producing 200 tpd, Deckle of 2500mm

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  • Product ID: VAK10586
  • Name: Paper Machine. Producing 200 tpd, Deckle of 2500mm

Machine was in operation until the end of 2008. STOCK PREPARATION Continuous Pulper (No.2)

  • 14’ Black Clawson, rated at 240 BD tonnes / day @ 3.5%
  • Junk trap, light rejects removed with overhead grab.
  • 2nd Hand unit , Installed in 1995
  • Stainless steel construction
  • 1.5 m wide feed conveyor
Ultrascreen
  • Black Clawson Ultra V400, installed 2000
  • 1st stage screen following 16’ pulper
  • 400 m3 / hour @ 3.5% = 14.0 tonnes / hour
  • 2mm holed extraction plate
  • 110 KW drive motor running at 600 RPM
Turbo Separator (No.1)
  • Voith ATS 021
  • 2nd stage screen on 16’ line, treating rejects from Ultrascreen
  • 70 m3 / hour @ 5.0% = 3.5 tonnes / hour (85 BD tonnes / day)
  • 205 KW drive motor
Screw Compactor
  • Beltec screw thickener supplied 2004
Elephant Filter
  • Meri - Model 3-10 (Now Voith)
  • 10-Disc unit, arranged in 5-banks of 2
  • Maximum flow rate = 24.0 m3/hour, 3.2 tonnes / day
Trommel Screen
  • Rotating drum design
  • 10 BD tonnes / day @ 1.4%
Vibrating Screen
  • 20 BD tonnes / day @ 5.0%
Thickstock Chest
  • 200 m3 stainless steel chest, installed 2000
  • 9.0 BD tonnes maximum stock holding at 4.5%
  • Side mounted agitator
  • 2 x Thickstock feed pumps, Scanpump BA 200/150 – 40, rated at 330 m3/hour
  • Consistency control
PM1 STOCK APPROACH – BOTTOM WIRE Refining
  • Jylhavaara JCO2 conical refiner
  • 5000 litres / min @ 6% = 18.0 tonnes / hour
Fan Pump
  • Scanpump BA 350/350 – 45
  • 17,200 litres / min @ 19.0m head
Primary Cleaners
  • 48 x Voith HC5 – TB36 Cleaners
  • 400 litres / min per unit = 19,200 litres / min total
Secondary Cleaners
  • 19 x Voith HC5 Cleaners
  • 400 litres / min per unit = 7,600 litres / min total
Tertiary Cleaners
  • 8 x Voith HC5 – TB1B Cleaners
  • 400 litres / min per unit = 3,200 litres / min total
Quaternary Cleaners
  • 4 x Voith Elutricone EBOB Cleaners
  • 400 litres / min per unit = 1,600 litres / min total
  • Continuous rejects
Final Stage Cleaners
  • 2 x Palmac P200 RFD Cleaners
  • 1,000 litres / min per unit = 2,000 litres / min total
  • Intermittent rejects
Primary Screen
  • Voith vertical screen Size 25
  • 0.25 mm slotted basket
  • 300 tonnes / day
Secondary Screen
  • Voith vertical screen Size 12
  • 0.20 mm slotted basket
  • 20 tonnes / day @ 1.0%
  • Common to top wire screening system
Rejects compactor
  • Fan press, size 4
  • Installed in 2004,
  • Maximum flow rate = 1,500 litres / min @ 5.0%
  • Maximum discharge solids content = 45.0%
PM1 STOCK APPROACH – TOP WIRE Refining
  • 2 x Metso JCO-1
  • 100 tonnes / day output (combined max)
Fan Pump
  • Scanpump BA 300 / 300 – 40
  • 15,300 litres / min @ 0.6%, 38.0m head
Primary Cleaners
  • 9 x Celleco TW 1500 combi cleaners
  • 1,540 litres / min per unit @ 1.1% = 13,860 litres / min total


Secondary Cleaners
  • 2 x Celleco TW 1500 cleaners
  • 1,400 litres / min per unit @ 0.9% = 2,800 litres / min total
Fibermizer
  • 528 litres / min @ 0.6%
Stage 1R Cleaners
  • 7 x LWR CLP 250 cleaners
  • 250 litres / min per unit @ 0.6% = 1,750 litres / min total
Stage 2R Cleaners
  • 1 x LWR CLP 250 cleaner
  • 225 litres / min @ 0.5%
Primary Screen
  • Voith vertical screen Size 20
  • 0.20 mm slotted basket
  • 15,000 litres / min @ 1.0% = 9.0 tonnes / hour
No.1 MACHINE General Description
  • Twin ply Fourdrinier machine with nominal deckle of 2,500mm
  • Built in 1986, with a maximum design speed of 600 m/min
  • SSD digital drive suite installed March 2005, L/hand drive.
  • Current maximum operating speed – 600 m/min (at reel)
  • Grammage range 90 GSM – 170 GSM. Production at 170 gsm = 10.5 t/hr.
  • Testliner and Un-Dyed Chip
  • ABB 1190 Advant DCS control system, with Smart Platform QCS dry-end scanner
Flowbox (Bottom Wire)
  • Simon Holder, rectifier roll flowbox
  • 18 x manually controlled slice positioners
  • Slice width – 2750mm
  • Consistency range – 0.65% - 0.85%
  • Flow rate – 11,000 litres / min (min) – 14,000 litres / min (max)
Wire Table (Bottom Wire)
  • Simon Holder, bottom wire Fourdrinier
  • Cantilever design
  • Part ceramic, part plastic drainage elements
  • Wire width – 2,900mm
  • Wire length – 45.5m, couch to breast roll centres 27 mtrs.
  • Single zone, suction couch roll with double doctor
  • Variable position forward drive roll
  • Steam profiling shower fitted over final tri-vac suction box
  • Exit moisture circa 22%
Flowbox (Top Wire)
  • Simon Holder, rectifier roll flowbox
  • 18 x manually controlled slice positioners
  • Slice width – 2,750mm
  • Consistency range – 0.45% - 0.55%
  • Flow rate – 5,000 litres / min (min) – 10,500 litres / min (max)
Wire Table (Top Wire)
  • Simon Holder, top wire Fourdrinier
  • Cantilever design
  • Plastic drainage elements
  • Wire width – 2,950mm
  • Wire length – 20.6m
First Press
  • Single felted, suction pick-up roll with 3 vacuum zones
  • 2 x UHLE Box’s, with herring bone design plastic tops
  • PU covered, with blind drillings and grooves
  • Vacuum assisted save-all tray
  • 450 PLi line load
  • Synthetic covered plain pressing roll with double doctor
  • Couch pit, with side entry agitator
  • Open draw transfer to 2nd press, via William Kenyons tail transfer system, installed 2005
  • Exit moisture circa 40%
Second Press
  • Large diameter jumbo press, 1.030 m diameter rolls
  • Rubber covered with blind drill pattern
  • Automated internal cooling system
  • 1750 PLi line load
  • Double felted
  • 3 x UHLE Box’s, with herring bone design plastic tops
  • Exit moisture circa 50%
Vacuum
  • 2 x Nash 901, installed 2000
  • 5 x Nash CL2001
  • 1 x Nash CL1001
  • 2 x 2-stage vacufoil fans for wire table low vacuum requirements
  • Pre-separators and pumps
  • Albany filter for recirculating seal water
  • Seal water temperature control
Dryiers
  • 3 x mechanical groupings arranged in 5 x steam sections: -
    • 1st Section – 3 x 1.2m diameter cylinders @ 1.8 barg
    • 2nd Section – 7 x 1.2m diameter cylinders @ 1.8 barg
    • 3rd Section – 10 x 1.5m diameter cylinders @ 5.3 barg
    • 4th Section – 5 x 1.5m diameter cylinders @ 10.0 barg
    • 5th Section – 11 x 1.5m diameter cylinders @ 5.3 barg
  • Potential to uprate 5.3 barg cyclinders to 7.5 barg, subject to re-cerification and insurance checks
  • Johnson Systems International, thermo-compressor based steam system
  • Steam groupings 1,2, 3 & 5 fitted with rotating siphons
  • Steam group 4 fitted with stationary siphons
  • Steam groupings 4 & 5 fitted with spoiler bars
  • Drier group 1 configured with unirun drier fabric
  • Drier groupings 2 & 3 configured with standard top & bottom drier fabrics
  • Open gear drive train with part plastic, part metal gear wheels
  • Partially enclosed hood with 2-fan PV System. Incorporates heat recovery from flash steam and condensate sources
  • Automatic fabric tensioning (E & L)
  • Automatic rope stretching (William Kenyons)
  • SSD touch screen HMI control stations, installed 2005
Calender
  • 2 x roll hard nip calendar
  • Top roll diameter – 295mm
  • Bottom roll diameter – 390mm
  • Design nip load – 100PLi
Reel-Up
  • Simon Holder drum reel
  • Capable of producing single set parent reels, maximum diameter 1.6m
  • Future upgrade potential to allow production of 4-set jumbo reels
  • 5-tonne overhead crane
  • UTM pulper with consistency control
  • IBS automatic sheet turn-up system
  • 30-reel spoils
  • Belt driven, reel spool speed up system
  • ABB Smartplatform scanner
  • Maximum gross deckle – 2,580mm
General
  • Anti-friction roller bearings throughout
  • Automatic grease lubrication system
  • Condition monitoring sensors installed on all major rolls, cylinders etc.
  • HP showers on wet-end and press clothing, fitted with ruby nozzles
  • Thermo compressors on dryers
  • DCS control on stock prep
  • Computer on machine ABB Advant 1190
Spares
  • All major rolls
  • Motors & gear-boxes for all drive positions
  • Full set of machine clothing
Finishing Rewinder
  • Masson Scott Autotorque, twin-drum winder
  • Maximum operating speed – 1,800 metres / min
  • 2 x unwind stations for tambours,
  • Unwind and rewind 1500mm diameter
  • Shaftless rewind
  • Brake driven tension control
  • Rider roll
  • Hydraulic reel lowering table
  • PLC controlled, Eurotherm drive system
  • Trim handling and conveying system
  • Trim bale compactor, circa 3 tonnes / day
  • Twin motor drive R/hand from unwinds
Backwater / Ancilliaries Dissolved Air Floatation Unit
  • Meri Deltafloat – Model 23, installed 1990
  • Floatation surface area = 23m2
  • Maximum flow rate = 185 m3/hour
  • Operating in partial pressurization mode
Drum thickener (No.2)
  • Hedomora drum thickener
  • Drum dimension – 0.75m diameter x 5.0m face length
  • Thickens from 0.8% to 4.5%
  • Spare drum
Heat & Power Generation Package boilers (Sold)
  • 3 x Maxicon package boilers installed 1971
  • Shell boiler design, each unit rated at 11.0 tonnes steam / hour @ 13.8 Bar
  • Co-fuel capability – gas and LFO Sold
Gas turbine CHP (Sold)
  • Ruston (Now Siemens) TB5000 gas turbine, rated at 3.5 MWe (Sold)
  • Purchased as an unused, second hand unit in 1986 from Shell. Originally constructed in 1981 (Sold)
  • Co-fuel capability – gas and LFO
  • Gas compressor designed to raise incoming gas pressure from 3.0 to 11.0 Bar
  • 33m Chimney
  • Waste heat economiser installed in 1993
  • Gas fired supplementary burner installed in 1993
Waste Heat Boiler
  • Natural circulation water cooled boiler, rated at 26.0 tonnes steam / hour @ 13.8 barg, installed 1993
Steam turbine
  • KKK steam turbine rated at 0.5 MWe @ 18tph steam flow
  • Installed in 1987
  • Steam pressure reduction from 13.8 barg to 2.8 barg
Gas engine CHP ( Sold)
  • Caterpillar, 16-cylinder gas engine, installed 1991, Hrs 92,500. Sold
  • Gas only
  • Rated at 1.0 MWe and 1.5 tonnes / hour steam at 1.0 barg
  • Hot water supply – 19m3/hour @ 40oC
Water Treatment
  • Twin stream de-min plant (1986), rated at 12m3/hour
  • Reverse osmosis plant (2001), rated at 12 m3/hour
General
  • Steam accumulator (1993)
  • Thermal de-areator (1993)
  • Air compressors – various
  • 5 x Oil-cooled transformers, stepping down from 11KV to 415V. Ratings: -
    • 2 x 1,000 kVA
    • 1 x 1,500 kVA
    • 2 x 2,000 kVA
    • 1 x 2,500 kVA
  • HT & LT distribution equipment for PM1
  • Power factor correction equipment
DVD AVAILABLE OF THE PLANT IN OPERATION All equipment was run on a 6 week maintenance cycle.

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