By Graeme Rodden, Executive Editor, Pulp & Paper International magazineWhen Green Bay Packaging found its automation systems ageing and struggling to communicate with each other, the mill needed to bring in a single unified approach. Turning to ABB for a solution, the goal was to increase productivity and continue improving quality at the same time. Read Part I here .
Founded and still owned by the Kress family, the company had its beginnings in 1919 when Frank Kress began making wooden boxes as a side business to his horse collar company. The mill’s paper machine is named the Marguerite K, the wife of George Kress (Frank’s son).
Green Bay Packaging produced saleable paper after three reels. With 30 minute turn-ups, this means the mill had saleable paper 1.5 hours after startup.
There were some specific objectives that the mill wanted to achieve. "We wanted to make a unified platform and increase production by improving our quality with better moisture profiles," says Vandenberg. "We wanted to eliminate the upsets and be more reliable."
According to Vandenberg and his team, the goals have been met. They credit the in-house engineering group for being critical to the success of the project.
The old moisture control system had 42 rows of four nozzles each. Maintenance was a tough task. Now, there are 56 rows with one nozzle per zone and air atomized showers. The water goes where
One of the things that helped get the project approved was the promised steam savings. In terms of cost, actual steam savings are projected to be about $0.5 million, or just over 8%, far above the 2.25% guaranteed.
Other improvements have come in bone dry weight CD control 2 sigma, moisture CD control 2 sigma, break recovery times, MD weight and moisture.
Some training was done at ABB in Columbus, OH. Four operators were sent there to see what they were getting. They had some input into the operating procedure. Training was also done in the mill so when it came time to start up, there were no surprises. The operators are very happy overall, adds Allen. "They trust the system."
Keeping colleagues happy
The majority of the production from this mill is utilized in its internal boxplants. "We have frequent feedback from our plants and they liked our sheet before," Vandenberg explains. "One of the goals was to reduce variation in basis weight and moisture and provide a more reliable product." Green Bay Packaging owns 15 container facilities across the US in its Corrugated Container Division. The mill's paper is used to produce corrugated containers of various types for fast food, tissue, soap, appliances and other industries.
What's next? The mill is rebuilding the fourdrinier table in 2011. IBS is the lead supplier. The mill is looking to maintain its strength and be able to offer the same properties at a lower basis weight, notes paper machine superintendent Pete Ross. This would result in fiber, chemical and further steam savings as well as reduced transport costs.
Green Bay Packaging is also looking at replacing its base fine screening system, which is 19 years old. There are other, smaller quality and reliability issues that are being studied. There is some concern about the US MACT regulations for boilers. The mill has a coal-fired boiler that, in the worst case, could need significant capital for control equipment to meet MACT limits. This would mean the natural gas-fired power boiler would have to be used. In any case, the mill is looking at a new control system for the coal-fired unit.
Environmentally, the mill has an enviable record. It is the first paper mill to close its water system. The work on this started in 1963. By 1972, it had a completely closed water system. After closing the pulp mill in 1991, the mill's water system was out of balance and the mill started to discharge to the local municipal treatment plant at a rate of 100 gal/min. (The mill does not have its own effluent treatment plant.) By September 1992, it had completely reclosed its water system.
The mill uses between 160,000 and 200,000 gallons of make-up water daily to account for evaporation in the drying process as well as the water content in various reject streams. There is a "huge" clarifier to clean white water.
This is a company that has not been afraid to be a leader and as Vandenberg says, "It's good to see that the company is willing to spend money in the mill on big projects."
The Green Bay mill uses 252,000 tons/yr of post consumer fiber, about 45-55 trucks daily. Yield is in the 92-93% range. Rejects include plastic, wax, metal, wood, nylon and Styrofoam. Most of the furnish comes from the mid-west, particularly the Chicago area. As it uses OCC, grocery stores play an important role in providing the mill with fiber. The mill has about 175 suppliers.
Pulp & Paper International is FREE to qualified subscribers. Click here to find out more.
