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Dong Il Wolsan PM1 Lightweighting with new
layering headbox
Jin-Doo Kim
Timo Saresvuo
Vice President
Dong Il Group
Senior Sales
Manager
Strengthening market leadership with new
technologies
 Valmet has tools to help
customers – new technologies
to support strategic needs of
customers
 Valmet and Dong Il Paper
Group: long co-operation
history - true partnership
 Mr Kim has been awarded for
Valmet Technology
Partnership
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Customer Days | Timo Saresvuo
OptiFlo headbox
 Launched two years ago
 40 sold so far
 Superior end product with
flat profiles, perfect visual
appearance & optimal
strength properties
 High productivity
 Economical – low lifetime
costs
 Security as an investment –
transformer – future
possibilities
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Customer Days | Timo Saresvuo
Even better OptiFlo with Aqua layering technology
Unique technology that uses a thin layer of water as a headbox
wedge to stabilize the layers and to form an even film while layers of
stratified paper are being joined together.
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Customer Days | Timo Saresvuo
Why Aqua multilayering with a single headbox?
Economic
Quality
Flexibility
 Raw material cost
savings
 Maintaining strength
while using lowerquality raw material
 Tool for optimizing end
product properties and
raw materials
 Boosting internal
bonding
 Flexibility with
chemical additives
 Lower investment
cost
 Energy savings
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Customer Days | Timo Saresvuo
Results with Aqua layering technology
Optimal dosage of additives for improved quality
strength properties (%)
Cationic starch
+ a portion of
refined fibers –
Aqua
technology
Cationic
starch –
Aqua
technology
Cationic
starch –
machine
chest
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5
10
15
20
Starch dosage (kg/t)
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Customer Days | Timo Saresvuo
Based on pilot trials, European OCC, testliner, filler
amount 10-15%
Aqua layering technology – improved strength
Optimal feeding point for active starch interaction
Conventional
starch configuration
Fiber
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Customer Days | Timo Saresvuo
Starch configuration
with Aqua technology
Fiber
Benefits of Aqua layering technology
Starch cost savings at same strength
Machine
chest
Aqua
10 kg/t
5 gsm
7 kg/t
5 gsm
Strength target
specification
= wet end starch dosage
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Customer Days | Timo Saresvuo
= surface sizing
Benefits of Aqua layering technology
Estimated savings per 100,000 t of containerboard production
Savings on starch
consumption
Up to
Savings from faster
system response
€300,000/yr
or
Up to
Up to
€480,000/yr
€30,000/yr
Savings on
cheaper raw
materials
Up to
€450,000/yr
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© Valmet
Total savings
Customer Days | Timo Saresvuo
Dong Il Paper
Wolsan PM 1 liner
production line
Ecxellent results with new OptiFlo
layering headbox
Mr Jin-Doo Kim, Vice President
Dong Il Paper Group
 Established 1986 in South Korea
 Privately owned
 CEO Jeong Yeong-Seop
 Four paper mill sites in Ansan,
Wolsan, Uiryeong and Dongwon
 Produces various containerboard
grades such as liner, testliner and
corrugated medium.
 Total production over 1 million
tonnes, mainly for Korean market
 Belongs to Tae Lim Packaging
– 10 converting plants
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Customer Days | Jin-Doo Kim
Dong Il Paper
Improved quality and significant cost savings
Dong Il Wolsan PM 1 wet end rebuild in Korea
Targets:
 Improve end product quality
 Even out variations caused by OCC
 Raw material cost savings
Solution:
 Key components for the rebuild: twolayer headbox and vacuum-assisted
forming board for middle ply
Results:
 Improved strength properties
 Good layer purity
 Operation - normal
 Significant mill-wide cost savings
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Customer Days | Jin-Doo Kim
Grade
Wire width
Desing speed
Basis weight range
Recycled liner &
kraft testliner
5,000 mm
1,200 m/min
120–300 g/m²
30% less starch needed with new Aqua layering
technology
 Flexibility
 Aqua has a rapid starch feeding response, unlike conventional
technology with a long delay time
 With Aqua layering technology, strength targets are achieved with
almost 30% lower starch dosing
 Aqua layering enables totally new ways to utilize raw materials, like
refined OCC, refined broke, selected fiber fractions or even reject.
This gives revolutionary improvement
possibilities
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Customer Days | Jin-Doo Kim
Wolsan PM 1 revolutionary example:
Signinificant cost savings and method of optimizing mill performance
 Reject from WWTP chemical flotation is returned directly to the Aqua layer
 This has offered totally new optimization possibilities on the furnish side
 Next phase is to utilize fines and fiber from white water
Recirculation of raw
material to Aqua layer
Liner machine
Raw material
OCC plant
Stock prep
Running model before layering headbox
Wastewater treatment
Sludge to disposal process
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Customer Days | Jin-Doo Kim
Future potential for Aqua layering technology
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White water
fines to be used
in Aqua layer
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Using optimized
OCC fractions for
each five layers
Optimization of
wet end sizing
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Customer Days | Jin-Doo Kim
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New functional
properties with new
chemicals: water
barrier
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New filler
chemicals
(polymers)
OptiFlo layering possibilities for other grades
FBB lightweighting
Fine paper
Kraft top liner
 Leave out chemical pulp
in the middle ply and
produce internal bond
with Aqua
 Increase the filler level
 Layering possibilities
using only one headbox
and forming section
 Higher freeness
BCTMP/mech pulp
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Customer Days | Jin-Doo Kim
Questions?
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© Valmet
Customer Days | Timo Saresvuo
Dong IL Paper