At its Longview, Wash., mill, an aggressive program for upgrading 12 paper machines has positioned Longview Fibre to produce value-added grades

Aggressive Strategy, Flexibility Boost Product Performance at Longview Fibre

Characterized primarily as a containerboard mill, Longview has spent in excess of $1 billion in capital improvements during this decade. A substantial portion of this was invested to upgrade its 12 paper machines, six of which were installed prior to 1955. About half of these upgrades were required to replace or refurbish older equipment, while the other upgrades were geared at fiber conservation and moving the mill toward the production of more specialized products such as performance linerboard, soft-calendered grades, and extensible papers.

With one of the largest single-site paper mills in the world, Longview faces a variety of unique problems, the most pressing of which is the rising cost for regional fiber. To combat this, the mill has supplemented the wide variety of wood species it uses with alternative furnishes such as recycle, urban wood waste, and a "chunk"-recovery program developed in Longview's and other timberlands. However, the use of these furnishes, along with the wide variety of wood species, has required upgrades in both the pulp mill and the paper mill to successfully produce more specialized performance grades.

Despite some limitations in remaining such a large, single-site facility, Longview president and CEO Richard P. Wollenberg feels that the positive aspects outweigh the negative, especially in terms of developing strategic responses.

"If our people feel the need for an investment, we can deal with it in a matter of days as opposed to weeks or months at a multi-mill facility, allowing us to react quickly to changes in the market and in technology," says Wollenberg. As in the ability to use a variety of fiber sources, the flexibility described by Wollenberg is evident in the mill's paper machines, several of which transition between producing paper and paperboard. With the recent upgrades, many of Longview's machines produce a wide range of basis weights and fluctuate between commodity and specialty grades.

"Our machines are not the largest in the world, so we try to enhance them in ways that companies with larger machines cannot afford to risk," states Wollenberg. "Fifty years ago, we made only two grades of paper, and today we make approximately 50, including valued-added and specialty grades. This flexibility is part of our overall strategy to remain competitive."

PRODUCTS AND STRATEGY. In 1927, the Longview mill started operations with a cylinder linerboard machine, followed shortly by another paper machine for producing bag grades in 1928. Now with 12 paper machines, the last of which was added in 1990, the mill's expansion has slowed somewhat due to space, fiber, and market limitations. Even so, the Longview mill has been able to gradually boost daily capacity in recent years to approximately 3,500 tons, depending on product mix.

Longview has demonstrated a commitment to remaining competitive through a program of continuous improvement and modernization. Since 1995, the mill has spent a substantial amount on its paper machines and in the pulp mill area to improve product quality, develop new markets, and replace or refurbish equipment. To accomplish these goals, Longview spent close to 1-1/2 times its depreciation in the years from 1995 to 1997, though market conditions have more recently forced a drop in expenditures to avoid excessive debt.

Strategy. Wollenberg notes that approximately half of the expenditures have been directed at quality or market development issues, while the other half were focused on replacing or upgrading equipment. A major factor when considering an upgrade, according to senior vice president-production and mill manager Richard J. Parker, is not just technology, but Longview's crucial fiber cost concerns.

"We are constantly trying to optimize our fiber resources throughout the whole process, whether it is cooking yield or whether it is paper machine efficiencies and scheduling to make sure the trim is right," explains Parker. "We also stay current with technology to make sure our products are competitive from both a strength and customer-functionality perspective."

Though Wollenberg acknowledges the lower capital costs of upgrading equipment as opposed to a new paper machine, he also describes the particular challenges of continuously upgrading paper machines in what he calls a "creeping expansion."

"With a new machine, everything from the headbox to the winder is matched appropriately to the size of the machine," explains Wollenberg. "With an older machine, you can purchase state-of-the-art equipment-such as a drive- that you might not be able to use to its maximum because of bottlenecks it could cause at other points on the machine. And it's always difficult to anti-cipate just what that next bottleneck is."

Products. The Longview mill currently produces around 50 grades of paper and board that have varying strength characteristics, moisture contents, surface finishes, appearances, and receptivity to glue, plastics, and advanced printing techniques. Products range from linerboard and corrugating medium, including Swedish Technical Forest Institute (STFI) test grades, to semi-extensible paper, wrapping paper, machine glazed (MG) paper, color specialties, and gumming and laminating grades (Table 1).

Since the Longview mill operates several smaller, older paper machines, it is flexible enough to balance production between specialty grades and its commodity base of paperboard and bag papers, depending on market conditions. Also, several machines at the mill are capable of producing both paper and paperboard, providing even further flexibility.

In 1998, Longview announced its exit from the grocery sack business at its bag plants to focus marketing efforts on a line of higher-value merchandise and handle shopping bags. Because of its access to recycled fiber, the mill is able to use a wide range of recycled content, attracting specialty bag customers such as McDonald's. Also, because of dual headboxes on all its linerboard machines, the mill can use old corrugated container (OCC) furnish in the bottom ply of its linerboard products to reduce costs.

Because it has some smaller machines, Longview has the flexibility for running short runs of colored stock. Although the mill has focused more on specialty type products and performance-linerboard products, Parker says Longview continues to be a high-volume linerboard mill. The mill currently produces linerboard and medium with basis weights ranging between 20 lb and 90 lb and papers ranging from 20 lb to 100 lb.

One specialized area that shows growth potential for Longview is the area of extensible papers, which are used in producing strong, multiwall bags for applications such as cement. In 1997, Longview added an extensible unit to its No. 11 paper machine and began producing a trademarked semi-extensible paper known as TEA-Kraft, which was named for the tensile energy absorption test that measures the stress units of such paper. In addition, machines No. 3 and No. 8 produce Longview's trademarked Ductlkraft ductile kraft paper, which also is microcreped and embossed to impart strength.

Wollenberg reports that specialty grades comprise up to 20% of Longview's production, including finished products produced at the company's box plants. Such specialty box products include recyclable pillar pallets that replace wooden pallets for shipping large items such as automobile parts, as well as point-of-purchase displays and small cubes used for protective packaging instead of plastic "popcorn." Because of recent major capital investments, Longview's box plants make microflute boxes, perform six-color printing, and do litho-laminating.

In 1998, the company introduced three- and four-color process printing capability at its bag-making plants. Since installing a soft calender on its No. 5 paper machine in 1995, Longview has offered soft-calendered bags that allow higher graphics reproduction on totally recyclable kraft bag papers.

Markets. Of the 630,000 tpy of containerboard produced at Longview, about 65% is absorbed internally by its own box plants. Although the company owns 11 corrugating plants, most of this production goes to the six in the West. The remainder of Longview's production is either bartered to provide materials for the eastern plants, or exported to Asia.

Longview's two bag plants in the east and west use a modest portion of company-produced bag papers. A majority of other papers are sold on the open market.

Key in the No. 5 paper machine's transition to specialty grades was the installation of a soft calender in 1995.

MEETING THE FIBER DEMAND. To supply up to 3,500 tpd of pulp for its 12 paper machines, Longview has upgraded its pulp mill with technology that meets both capacity and environmental requirements. In addition, the mill has explored alternative fiber sources to expand supply in its region.

Fiber sources. Due to competition from other users of wood wastes in the Pacific Northwest, Longview must creatively adjust to a variety of wood species and recycled furnishes. While the predominant wood species is Douglas fir, the mill also uses other firs, western and mountain hemlock, various pines, and a number of other wood species, including hardwoods. However, Longview has been accustomed to dealing with such variety since the company was formed in 1926. At that time, Longview was the first mill to use sawmill waste to produce unbleached linerboard and sack paper.

To make 2,500 tpd of kraft pulp, Longview receives chips from about 75 sawmills and other solid-wood plants in a 1,300-mile radius of the mill. The chips are delivered by truck, rail, and barge. At the mill, the chips are placed in separate piles according to species and are tested for quality. The various types are screened and pulped separately and placed in high-density storage until they are used for an appropriate grade. To improve its kraft pulping system, Longview spent $2.5 million on a new Beloit-Rader chip-thickness screening system in 1997.

In addition, a $20 million Sunds Defibrator semi-chemical pulping and Black-Clawson washing facility was installed at Longview in 1997. This facility currently produces 400 tpd of neutral-sulfite semi-chemical pulp (NSSC). This pulp is primarily used for corrugating medium.

To reach a maximum of 3,500 tpd in paper machine production, Longview has developed alternative fiber sources such as old corrugated containers (OCC) and urban wood waste. In the 1990s, the mill twice upgraded its 300 tpd OCC plant and, by 1995, the state-of-the-art operation reached a capacity of 800 tpd. Longview can produce packaging grades that range from a few percent to 100% recycled content, with its brown grades having an average recycled fiber content of 20%. The urban wood waste used at Longview comes from old pallets and construction lumber ends and pieces, and the mill has a system that uses this material for furnish in NSSC and kraft grades.

The Longview mill also uses precipitated calcium carbonate (PCC) as a filler in its linerboard and paper to enhance products. Filler content ranges from 1% to 3% , and is used to offset fiber requirements and impart specific characteristics in neutral pH grades.

In 1994, Longview shut down its chlorine bleaching plant due to pending environmental regulations, choosing not to spend the required $45 million for upgrades for products used in very limited quantities. However, the mill still uses 3,000 to 4,000 tons of bleached market pulp each month that is purchased from both foreign and domestic sources.

New pulp mill equipment. Longview's major steps toward modernizing its pulp mill came in 1983 and 1988 with the addition of two Kamyr continuous digesters and pulp washing, which include a Foxboro distributed control system. According to Parker, these digesters have contributed a great deal to the mill's ability to handle the varying wood species by improving cooking control and pulp quality.

Parker reports that Douglas fir, white fir, and pine are cooked at low kappa numbers (30 to 40) to produce high quality, clean paper stock used in making laminating or gumming papers, while other species are cooked at higher kappa numbers (60 to 70) to make generic linerboard. In addition, the mill runs 6 batch digesters, and has the capacity to run 15 if needed.

In 1992, the $100 million No. 22 recovery furnace with 1,250 tpd capacity was installed at Longview. This low-odor, high-solids burning boiler was purchased to meet capacity requirements from the new No. 12 paper machine, as well as to meet environmental regulations and achieve energy savings. In the last five years, the mill has retired its No. 11 and No. 14 furnaces and has spent $25 million rebuilding the No. 15 and No. 18 furnaces to meet environmental constraints. These upgrades involved Combustion Engineering rebuilding the boiler water walls and boiler section, as well as installing new wet bottom precipitators.

PAPERBOARD MACHINES. Of its 12 paper machines, Longview has dedicated its No. 1, No. 6, No. 7, and No. 10 machines to the production of linerboard and the No. 4 machine to the production of corrugating medium. Ranging in age from 35 years to 72 years, with trim widths from 136 in. to 242 in., these machines can produce a total of about 1.2 million tpy. All incorporate a secondary headbox for a two-ply sheet and have closed loop basis-weight and moisture-control scanning systems from Honeywell-Measurex.

Since 1995, Longview has spent more than $50 million upgrading its paperboard machines. Improvements range from secondary headboxes and other wet-end equipment to dryer, winder, control system, and roll conveyor technology. Most of the upgrades were to replace old, even obsolete equipment, although several were focused at quality and capacity increases.

"We have aimed many improvements at the ability to build a good profile in our base sheet utilizing an inexpensive furnish," says Parker. "This improves our ability to lay down that top stock layer for better smoothness characteristics."

In addition to using it as a filler to offset fiber costs, the mill uses PCC as a means for controlling slide angle and smoothness on its linerboard. This allows the mill to make products that fit specific customer demands.

Currently STFI grades are made on several paper machines. However, Parker reports that, depending on market conditions and capital spending, it is a near-to medium- term goal to upgrade each paperboard machine at the mill so that it can easily produce these performance grades.

No. 1 paper machine. When it began producing heavyweight linerboard in 1927, the No. 1 machine produced 75 tpd and ran at 400 fpm. Since that time, the machine, which has a 136-in. trim width, has undergone numerous rebuilds to improve pressing, along with the addition of dryers, including high pressure dryers. Also, it was converted from a cylinder to a fourdrinier wet end in 1964. Currently, the No. 1 paper machine produces 400 tpd of 42 lb to 92 lb linerboard at speeds of up to 1,100 fpm.

More recent upgrades for the No. 1 paper machine include the addition of a dryer bearing lubrication system in 1995 that was created by Longview Fibre with help from several suppliers, which has reduced maintenance costs. In addition, the mill added a VID unit for vacuum assisted forming from AES Engineered Systems (see "Cooperative Technology Improves Sheet Formation at Longview Fibre," Pulp & Paper, March 1999), a technology that has been installed on several machines at Longview. Also, the forming table was rebuilt in 1994 to include AES low vacuum suction boxes instead of table rolls.

According to Parker, these recent upgrades have improved strength and provided a better base sheet profile out of the dual headbox machine, allowing the mill to explore different applications and markets with the product from this older paper machine.

"We made relatively simple changes that have allowed us to go from a marginal quality to a very acceptable quality as far as printability and smoothness-just in the past five years," describes Parker. "Also, we now meet strength requirements for both domestic and export customers, with the No. 1 machine's product being used, for example, in beer cases and in boxes for the electronics industry that require high quality, uniform printability."

No. 4 paper machine. With a trim width of 140 in., the No. 4 paper machine is Longview's only machine dedicated solely to the production of corrugating medium.

Starting in the mid 1990s, it underwent $5 million in upgrades aimed at increasing production and improving quality.

Originally installed in 1936, the No. 4 paper machine was converted from a cylinder machine in the 1950s. Additional improvements in 1995 included the installation of a Black Clawson C-former. To handle increased production, a dual-drum Jagenberg winder that operates at 6,000 fpm was installed in 1996. A Black-Clawson pulper was added to the No. 4 machine in 1996. In addition, a Jones DD double-disc refiner and stock preparation controls were purchased for the No. 4 paper machine in 1999 to improve sheet quality and strength characteristics of the corrugating medium, which ranges in basis weight from 23 lb to 40 lb.

No. 6 paper machine. In 1998, Longview Fibre spent $10 million rebuilding its No. 6 machine, which was originally installed in 1951 and currently produces 36 lb to 69 lb linerboard. The upgrade included a rebuild of the machine drive and dryer section improvements from General Electric. Also included were a GL&V saveall and Honeywell-Measurex stock system computer controls. And, as with the No. 1 paper machine, forming table improvements included a transition from table rolls to high vacuum/low vacuum suction boxes.

Improvements in the dryer section were focused on installing felts and upgrading the second section drive. According to Parker, this upgrade has significantly improved sheet quality on the No. 6 paper machine.

"Because there were no felts, we were getting all kinds of different strength, stretch, and tensile properties across the full web," describes Parker. "The new restrained drying has gone a long way toward improving those problems."

For the drive rebuild, which incorporated new electronic technology from General Electric, Longview's large in-house engineering department functioned as prime contractor, coordinating work between a variety of electrical contractors. The old line shaft driven arrangement with pullies was replaced by an electronic drive. Parker reports that, in addition to replacing the outdated equipment, operators are maintaining much better control of the paper machine due to the new computer systems associated with the drive. The No. 6 paper machine currently averages 500 tpd, which demonstrates a 10% increase since the upgrades.

No. 7 paper machine. In 1991, the No. 7 paper machine was upgraded with wet end drainage improvements and a new Beloit hydraulic headbox. These drainage improvements included a switch from table rolls to high-vacuum/low vacuum suction boxes, as on the No. 6 paper machine. In 1998, the forming section was further improved with the addition of an AES VID unit (see Pulp & Paper, March 1999).

The No. 7 paper machine, which has a 167-in. trim width, now produces 550 tpd of linerboard with basis weights ranging from 36 lb to 77 lb. In addition, due to the Sulzer Papertec Shoe Intensa-S press that was installed in 1987, Longview can produce STFI performance grades on the No. 7 machine. The press runs at loads of over 6,000 pli, depending on the grade, and Parker reports that Longview has benefited from the technology.

"The extended-nip press has allowed us to achieve our goals of utilizing fiber efficiently and achieving the desired strength characteristics, particularly in the cross direction," describes Parker. "Also, because it allowed us to increase speed, it improved our productivity. As a result, we are looking closely at that technology for our other linerboard machines, especially as the industry moves toward performance linerboard."

No. 10 paper machine. Since it was installed in 1964, the No. 10 paper machine has had a number of partial rebuilds. However, its largest rebuild occurred in 1998 with the installation of a Beloit Bel-Liner secondary headbox to produce a two-ply sheet. Other wet-end improvements from Beloit included a secondary stock cleaner system. Total spending for the rebuild was $25 million.

The No. 10 paper machine has 242-in. trim width and produces 700 tpd of linerboard in basis weights ranging from 21 lb to 42 lb. It was originally a swing machine between paper and paperboard, although, with the addition of the secondary headbox, it now only produces linerboard. In the mid-1990s, Longview decided to upgrade the machine to make it more productive and more efficient in its use of fiber. However, the company realized that a new winder and roll conveyor system would be required to handle the increased production.

In order to avoid large capital outlays, as well as to avoid the startup of several new pieces of equipment at the same time, the company chose to first install the new Jagenberg winder and Lamb-Grays Harbor roll conveyor system in 1996. The winder is a dual-drum winder that allows for tension control and high speed. After a somewhat rocky startup, it has performed well and similar computerized tension control and winding technology has been installed on the No. 11 and No. 12 winders.

In 1996, improvements from the installation of the new No. 10 dual-drum winder with computerized tension control led to the installation of similar technology for the No. 11 and No. 12 winders.

The automated roll handling system takes rolls from the No. 10, No. 11, and No. 12 machines in Longview's east mill-wrapping, end-covering, labeling and transferring them to storage and shipping. The east mill contains Longview's three largest paper machines, and the system is capable of handling more than 100 rolls/hour.

After the Bel-Liner installation, Parker reports that the goals for increased productivity were met, with the No. 10 paper machine setting production records. In addition, basis weight increased from 33 lb to 42 lb with the two-ply sheet and the improved drainage capabilities provided by the new equipment. Parker also notes that these improvements have given the mill more flexibility in using alternative furnishes.

TRANSITION MACHINES. Three of Longview's paper machines-the No. 5, No. 9, and No. 11-transition between producing paper and paperboard. These machines are between 26 years and 58 years old, and have trim widths ranging from 167 in. to 238 in. Due to nearly $50 million in improvements during the past five years, these machines now produce some of Longview's most specialized products, including soft-calendered grades and the company's trademarked semi-extensible papers.

No. 5 paper machine. Longview's No. 5 paper machine was originally installed in 1941 as a swing machine between paper and paperboard. As paper machines became longer and faster, the mill began looking for ways to produce more specialty grades on the smaller No. 5 machine, which has a trim width of 185 in. Since 1995, approximately $11 million has been spent on upgrades for this machine.

Key in the No. 5 paper machine's transition to specialty grades was the installation of a Voith Sulzer soft calender in 1995, along with Honeywell-Measurex computer profile and caliper controls. However, in order to achieve the even caliper required for the high-gloss soft-calendered grades, Longview had to address forming and press section constraints.

Located with paper machines No. 1 through No. 4 in the original portion of the Longview mill-the west mill, the No. 5 paper machine had suffered from space constraints since its installation. In 1987, a dual nip Escher-Wyss press was installed, and, in order to fit it in the space-restricted area, it was necessary to place it upside down. To correct caliper problems in order to produce smooth soft-calendered grades, Longview rebuilt the press section and fourdrinier table in 1997 to include a Voith Sulzer DuoCentri II press with self-loaded Nipco rolls.

"We were frustrated for a number of years, and then decided that if we were to be serious about making specialty grades, we had to turn this press around," states Parker. "So, we redesigned the sheet run, took the rolls out, replaced the frame, and rebuilt the entire press."

Currently, the No. 5 paper machine successfully produces specialty soft-calendered grades at 125 tpd and linerboard grades at 300 tpd, ranging in basis weight from 26 lb to 42 lb. In addition, it makes packaging papers that range in basis weight from 20 lb to 60 lb. Further adding to the No. 5 machine's flexibility is a color-mixing system that allows production of color bleach grades.

No. 9 paper machine. Earlier this year, the No. 9 paper machine at Longview, which produces both linerboard and corrugating medium, underwent a $6.5 million upgrade to replace outmoded equipment and improve paperboard quality. Included in this upgrade was a Jones DD refiner to improve fiber development, which, along with four new dryers, improved sheet strength. In addition, the No. 9 paper machine's drive was rebuilt by General Electric, since parts were unavailable for the existing one. The new electronic drive has increased machine capacity by about 10%. However, the mill cannot take full advantage of the speed potential until some additional equipment is installed. The No. 9 paper machine currently produces 300 tpd of linerboard and corrugating medium in basis weights ranging from 20 lb to 42 lb.

No. 11 paper machine. Longview's most flexible transition machine is its No. 11 paper machine. Installed in 1973, this machine, which has a 238-in. trim width, was recently upgraded at a cost of more than $30 million.

Figure 1: To produce Longview's TEA-Kraft semi-extensible papers, the new extensible unit imparts a microcrepe by applying pressure to the top of the sheet through a rubber blanket.

In 1996, the No. 11 winder was upgraded to include computerized winding and tension control similar to that on the new No. 10 winder. To allow production of multiwall shipping sack papers, a $13.5 million Beloit extensible unit was installed to produce Longview's trademarked TEA-Kraft semi-extensible papers in 1997 (Figure 1). Located between the 29th and 30th dryers, this unit imparts a microcrepe to the paper by applying pressure to the top of the sheet through a rubber extensible blanket. This blanket runs at slower speeds than the extensible dryer beneath the sheet, creating the stretchable creping.

In addition to the winder and extensible unit, the No. 11 machine received two Sunds Defibrator high-consistency refiners at a cost of $11 million in 1998. These 7,000 hp refiners were installed to provide the energy to develop the required tensile properties.

In addition to winder upgrades and a new extensible unit, the No. 11 machine received two high-consistency refiners at a cost of $11 million in 1998.

With its upgrades, the No. 11 paper machine can now produce grades ranging from 40 lb multiwall papers to lightweight linerboard and corrugating medium. Currently, about 50% of the No. 11 machine's production is TEA-Kraft and multiwall paper, and the balance is linerboard and corrugating medium.

PAPER MACHINES. Longview's paper machines range from one of its oldest -the 71-year-old No. 2 machine-to the newest No. 12 paper machine installed in 1990. Although these predominately produce paper, they are also capable of running corrugating medium if required. While some of the older and smaller machines do not run the entire year, they do provide Longview the flexibility to make specialty grades in small lots as needed.

No. 2 paper machine. In 1994, the No. 2 paper machine, which has a 162-in. trim width, received a new Sam Yang Yankee dryer (made in Korea) to improve the quality of its white and brown machine glazed and school papers.

Honeywell-Measurex wet end slice and computer controls were also purchased in 1996 to enhance paper quality. The machine capacity is 90 tpd.

No. 3 paper machine. One of Longview's smaller machines with a trim width of 83 in., the vintage 1932 No. 3 paper machine was used for making short runs of color stock prior to 1995. At that time, the market for such papers began declining while it appeared that the market for ductile kraft papers was on the upswing. To take advantage of this perceived growth market, a General Electric drive and an extensible unit that included a creping roll and embossing press was installed.

Other upgrades to the No. 3 paper machine for quality reasons include a new Honeywell-Measurex PLC and a new dandy roll and table elements that were installed in 1996.

The No. 3 machine makes specialty wrapping papers and helps support Longview's Ductlkraft needs, producing about 50 tpd.

No. 8 paper machine. Originally installed as a toweling machine in 1960, the No. 8 paper machine became the first machine to produce Longview's Ductlkraft ductile kraft papers when a creping roll and embossing press were installed in 1987. In 1996, the machine received an upgraded Honeywell-Measurex computer control system. The No. 8 paper machine currently produces 75 tpd of Longview's Ductlkraft papers.

No. 12 paper machine. Installed in 1990, Longview Fibre's newest paper machine, the No. 12, produces lightweight bag, wrapping papers, and masking papers at speeds of up to 3,000 fpm. The $90 million, 243-in.-trim Beloit machine produces up to 450 tpd of both natural and recycled kraft papers, and features a Concept III hydraulic headbox and Beloit press and dryer section. Its production is focused at laminating and packaging grades.

In 1996, drying capacity was added to the No. 12 machine in the form of six new dryers. In 1999, the HCR refinerpress section will be upgraded. Both projects increase production, with the combined costs approximating $5 million.