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Valmet's Recent Calender Technology

Article · March 2015

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Hidehiko Yamazaki Jari Ilomaki

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 Valmet’s recent calender technologies
- High bulk calendering, OptiCalender Compact and effective machine
calender rebuilds -

Hidehiko Yamazaki
Valmet K.K.
Jari Ilomaki and Ville Tiistola
Valmet Technologies, Inc.

Abstract
In recent years, the papermaking industry is increasingly demanding calendering
technologies for achieving more efficient and cost-effective production and energy and
raw material savings. Valmet has developed new technologies in various areas for
calendering.
This paper introduces three major topics for calendering. First, high bulk
calendering using newly developed aqua cooling technology is described. Second,
OptiCalender Compact, fully standardized with simplified specification, which has many
benefits, such as easy start-ups, every day site operations as well as maintenances is
described. Third, typical examples of machine calender rebuilds are described.

1. Introduction
In recent years, the practical technologies to reduce energy consumption and save raw
materials efficiently achieving target paper qualities have been demanded in wide range
of paper machine sections, and the technologies for satisfying the requirements have
been developed.

In this paper, 3 topics of recently developed technologies concerning calenders are

introduced. First, high bulk calendering using newly developed aqua cooling
technology is introduced. This technology, which is applied to cool the web before
calendering, enables paper-/board-makers to save 2-4% bulk attaining their target
smoothness, compared to conventional calendering methods. By saving bulk, the
amount of raw materials can be reduced, which leads to the cost reduction of raw
materials as well. Second, OptiCalender Compact is introduced. The calender is
modularized with simplified design, and the significant reductions of both investment
and operation costs are achievable compared with conventional calenders. Third, the
economical rebuilds of existing machine calenders are described.
2. Recent topics of calender technologies
Valmet supplies various types of calenders according to required applications (Fig.1).
Multinip calender (OptiCalender Multinip) is applied to demanding calendering of
coated paper, SC paper, release paper and so force. Metalbelt calender (OptiCalender
Metalbelt) enables to achieve macro smoothness and save bulk as a final calender for
uncoated papers and boards, and as a pre-calender for coated boards. We have a lot of
delivery experience of soft calender (OptiCalender Soft) to achieve excellent surface
smoothness for various paper grades. Hard nip calender (OptiCalender Hard) is
applied as a pre-calender and a final calender for various grades.

Fig.1 Valmet OptiCalender family

Accordingly, each calender type has its own use depending on concerned paper grades,
target paper quality level and location to be operated as a pre-calender or a final calender.

Here, we describe :
Aqua cooling technology which was newly developed for high bulk calendering,
OptiCalender Compact, economy-oriented compact calender with the structure and
specification simplified by standardization and modularization confining the user’s
target and use, and the economically efficient rebuilds of machine calenders
accompanied by changes in paper grades / operating conditions.

2.1 Advanced high bulk calendering technology with Aqua cooling solution
Recently Valmet developed Aqua cooling technology for calendering web with saving bulk.
If the web is calendered to achieve a target smoothness with the web cooled before the
calender nip, the compression of inner structure of the web is restrained and the bulk
is saved. (Fig.2）.
Fig. 2 High bulk calendering with Aqua cooling technology

2.1.1 Principle of Aqua cooling technology

Principle of Aqua cooling technology is shown in Fig. 3. A water-spraying equipment in
which specially arranged nozzles are placed with a given interval in cross direction, gives
necessary amount of water droplets on the web surface. And, within the short dwell
time interval before the capillary absorption of the sprayed water starts and the water
penetrates into paper structure, the web is dried quickly with high speed air jet, which
results in cooling the web with heat of vaporization drawn.

Fig. 3 Principle of Aqua cooling technology

As a background principle, it is generally known that when water is applied on a paper

surface the wetting delay time (tk) required for wetting the paper surface with some
degree of roughness exists before water penetration into capillaries of paper starts 1).
Normally, tk depends on surface characteristics of paper, which is sometimes roughly
in the order of 100msec. It is generally supposed that after t k has passed, water
penetrates into paper in proportion to square root of time according to Lucas-Washburn
equation which explains capillary penetration of liquid if swelling does not occur.

In the Aqua cooling technology, water is actively evaporated before the capillary
absorption proceeds, in other word, within wetting delay time. Accordingly, fiber-to-
fiber bonds of paper are not broken during the process of wetting, and web temperature
decrease is effectively achieved with heat of vaporization drawn with air jet blows.
PowerChill web cooler is used for the equipment (Fig. 2 left) giving high speed air jet for
web cooling. PowerFloat Plus nozzles, which has high heat transfer capacity used for
air dryers, are applied with high evaporation efficiency and facilitate web cooling (Fig.
4). Although near the inlet of air jet the temperature decrease in the web surface is
greater than that in the web inside, the whole web temperature decreases during the
process of web running to reach almost the same temperature level. (Fig. 3).

(a)PowerFloat Plus nozzle (b) Relative heat transfer coefficient

Fig. 4 PowerFloat Plus nozzle used for PowerChill

Fig. 5 shows the comparison in cooling effect between Aqua cooler and normal air-chiller,
indicating the simulated web temperature change as a function of time. In Aqua cooling,
5 g/m2 of water per side at 50 degC was applied to a board, and soon after that the board
was cooled losing vaporization heat with air jet 50 m/s. In air-chiller cooling, a board
was cooled only with air jet 50 m/s. Basis weight of the board was 240g/m2 and web
speed was 600 m/min. The result clearly shows that Aqua cooler gives 20 degC lower
temperature than air-chiller, compared at 3 m distance from the inlet of the cooler in
each case.
Fig. 5 Simulation results for comparison in web cooling capacity between Aqua Cooler
and air-chiller

2.1.2 Backgroud of the effectiveness of temperature gradient calendering

The temperature gradient calendering is based on the fact that when a paper web is
contacted with a thermo roll at a given nip load, the surface temperature of the web
containing cellulose, lignin and hemi-cellulose exceed the softening temperatures of
these constituents to cause thermal plastic deformations. Besides, if the temperature
of the middle layer of the web is kept lower, the layer undergoes elastic deformation
mainly under the nip. In the nature of surface treatment, the plastic deformation of the
deep insides of the paper web structure is not required. It is preferred for saving bulk
of products that plastic deformation in the inner layer is not caused by keeping the
temperatures below the softening points even under the nip.

Fig. 6 shows the relationships between moisture contents and softening temperatures of
cellulose, lignin and hemi-cellulose 2). Softening points of these materials tends to
decrease with increasing moisture content. Contacting with a heated thermo roll of
calender, the softening point of paper surface decreases with moisture content, and a
target smoothness is achieved due to thermal plastic deformation under the calender nip.
If the inside temperature is kept lower, the middle layer of paper does not undergo plastic
deformation, but undergo mainly elastic deformation.
Fig. 6 Softening temperatures of paper web constituents2)

Fig.7 shows these calendering effect schematically, where the web surface undergo
thermoplastic deformation and the elasticity and bulk are saved by keeping the web
inside at lower temperature.

Fig. 7 Schematic diagram showing bulk calendering

2.1.3 Calendering effect of Aqua cooling

The result obtained with the application of Aqua cooling technology to FBB (200g/m2) is
shown in Fig. 8, giving Bendtsen roughness change when speed is 600m/min, thermo roll
surface temperature 200 degC, and nip load changed from 30 kN/m to 150 kN/m. If
compared at the same Bendtsen roughness level (150ml/min) after calendering, bulk was
1.72cm3/g at an incoming web temperature of 65 degC, while bulk was 1.78 cm3/g at an
incoming web temperature of 36 degC after cooling the web from 65 degC. This means
that extra 3.5 % bulk can be obtained with Aqua cooling. 2 – 4 % bulk saving was
confirmed from various experiments.

Fig. 8 High bulk calendering with Aqua cooling (Relation between Bendtsen roughness
and bulk of FBB)

Fig. 9 shows the relationships between PPS roughness and bulk of final FBB product,
where the mill reference rolls produced at 85 degC, the pilot rolls heated to 65 degC, the
pilot rolls heated and then cooled to 35 degC with Aqua cooling and the cold pilot rolls
are calendered under different nip load conditions. It was found that comparing the
results with and without Aqua cooling, 2 – 4 % bulk could be saved at the same PPS level.
Fig. 9 Relationship between PPS roughness and bulk of final FBB product

These results show that 2 – 4 % bulk can be saved when papers with the same
thickness as before are produced, resulting in 2 – 4 % raw material saving, which is
directly connected to raw material cost reduction.

In addition, the effectiveness of this calendering technology was already proved using a
pilot machine in Valmet Technology Center at Jarvenpaa. Pilot trials can be carried
out extensively for customers under various calendering conditions using paper/board
grades according to respective targets at the Technology Center.

2.1.4 The first machine equipped with Aqua cooling technology

The first Aqua cooling technology will be installed in Stora Enso Ingerois BM4. After
the rebuild, the machine is scheduled to start up in September this year. BM4 has 3-
ply forming section and on-line coating stations, producing double coated FBB. Aqua
cooling technology is newly installed to cool down the web before the nip of the pre-
calender. Fig. 10 shows a schematic view, where the web is sent to Aqua cooler after
drying at the dryer section, and cooled down with the cooler, and then, pre-calendered,
and doubly blade-coated at the coating section. Max. speed for the lightest grade today
is 750m/min.
Fig. 10 Aqua cooler to be installed just before a pre-calender of board machine

2.2 OptiCalender Compact

Acquiring necessary functions of hard nip calenders, the simplified design to fulfil the
calendering needs for linerboards and coated boards were put into practice. Nip loading
is done with large pneumatic bellows for linear loads below 70 kN/m, while hydraulic
loading is used for linear loads above 70 kN/m. Steam-heating is used for thermo roll
surface temperatures below 130 degC, while oil-heating is used for thermo roll
temperatures above 130 degC. We can offer cost-effective choices applying plug-in-play
method to customers by taking in these criteria. Since OptiCalender Compact, which
is greatly simplified and modularized, is pre-assembled in our factory, it is possible to
instal the calender in shorter period as accorded with container sizes (Fig. 11). The
simplified structure makes the calender extremely easy to use, run, assemble and
maintain. There are two typical module dimensions in web width, and applicable linear
load ranges are 10-70kN/m, loaded with large pneumatic bellows.
Fig. 11 OptiCalender Compact

The structural features are as follows.

・ The simple, integrated structure enables extremely easy start-ups, everyday site
operations as well as maintenances.
・This also lowers the required project and operational costs.
・All components have been designed to function together seamlessly, which limits the
amount of modifications available for this calender model.
・With a more fixed calender module it is possible to integrate all parts of the design into
one single unit.
・No additional devices need to be placed in the basement or, for example, a separate
automation module
・The amount of containers in the delivery decreases from 15+ to 3.
・The whole project is standardized from start to finish to ensure a fast, smooth delivery.

Rough module dimension ranges for the project are presented below.

Table 1 Application ranges of OptiCalender Compact

The calender is modularized, so that investment and operation costs are reduced. Web
width is 5650 mm or 6660 mm, nip load ranges 10-70kN/m, speed maximum 1000m/min,
surface temperature of thermo roll 90-150degC. The calender is applicable for soft nip
and hard nip.

All the connections that need to be made on site are shown in Fig. 12.

Fig. 12 All the connections that need to be made on site

Fig. 13 Simplicity of OptiCalender Compact (right) compared to high-end calender,

OptiCalender Hard (left)
As shown in Fig.13, OptiCalender Compact is designed with modularized for suitably
limited application range, so that the calender structure is greatly simplified and
compact compared to conventional calenders.

Thermo roll is heated by steam for increased cost efficiency, and the integrated heating
system uses paper making line steam supply. The thermo roll is driven from both sides
without separate drive foundations. The integrated drives don’t require any alignment
or foundation building at customer site. A deflection compensated roll used for the
bottom roll is a swimming roll type with a rotating outer shell (Fig. 14).

Fig. 14 Swimming roll (Sym roll)

Nip loading is done with large pneumatic bellows, which have no external seals and there
is less friction, so that loading is more accurate. Air is taken into use from the mill’s
pneumatic system. All machine controls have been built into the calender control panel.
All the pumps and valves required to control the machine’s pneumatics and hydraulics
are located inside the control box.

Tail threading is optional and designed as a two phase, ropeless threading (Fig. 15).
Basic principle is based on the application of revolutionary foil effect, where air is blown
out of the foil underneath the belt to create a vacuum inside, so that web is sucked on
the belt surface. Thereby, this belt transportation makes secure web transport to next
position (Fig. 16).
Fig. 15 Ropeless tail threading solution, FoilForce1

(a) Appearrance (b) Principle of vacuum creation by foil effect

Fig. 16 FoilForce1

2.3 Machine calender rebuilds

The requirements for rebuilding existing calenders are as follows.
- Change in paper grade
- Changes in furnish
- Speed increase
- Quality improvement: gloss / bulk / profiles
- Calender vibrations / barring
- Tail threading problems
We can arrange tailor-made scopes according to customer targets, which include
followings, for example.
- Reduction in number of rolls
- Change from hard to soft nip
- Changing calender loading from hydraulic to pneumatic
- Modernization of tail threading
- New profiling tools: SymZ/CD rolls or IQInduction profiling beam
- Increase of thermo roll temperature
- Addition of quality improving elements, such as new loading system
- Modernization of calender automation and user interface

Accordingly, there are supposed to be various types of machine calender rebuilds. Some
of them are described below.

2.3.1 Reduction in number of rolls

An example of the rebuilds is shown in Fig. 17. In this case, the machine calender
originally has 4 rolls. Then, the number of rolls is reduced to 3 rolls after the rebuild.
This is because less calendering is needed due to increase in DIP amount. The rebuild
also includes: New tail threading roll, new hydraulic loading equipment, existing
bottom SymZS roll used, loading hydraulics and roll control modified and profiling errors
corrected.
Fig. 17 An example of machine calender rebuilds (from 4-roll to 3-roll stack)

Fig. 18 shows another example of machine calender rebuilds. There is possibility to

run with 3 nips, 1 nip or no nip at all, where it is needed to produce bulky book paper
with news machine. The rebuild includes: new hydraulic loading equipment, new
spreader roll, new tail threading plates, and calender loading and roll control modified.
Fig. 18 An example of machine calender rebuilds (3 nips, 1 nip, or no nip at all)

2.3.2 Improvement of profiles

In the case where calender profiles are to be improved and/or there is possibility to run
higher speeds with bigger diameter rolls, zone controlled rolls with higher functions are
applied (Fig. 19 and Fig. 20). Fig. 19 shows historical development of zone-controlled
rolls, including fixed crown roll, adjustable crown roll (Sym roll), zonewise controlled
crown roll (SymZ(S) roll) and shoewise controlled crown roll (SymCD(S) roll).
Fig. 19 Schematic overview of DC rolls with different functions

Fig. 20 Structural overview of DC rolls with different profiling functions

2.3.3 Improvement of tail threading function

In the case of machine calender rebuilds, FoilForce1 tail threading system is applied for
more efficient tail threading, shortening of tail threading time and improved safety.
Conventional rope or plate threading can be replaced with FoilForce1. High under-
pressure levels can be attained with vacuum compressed air operated, which secures tail
transportation. (See 2.2)
2.3.4 New heating-cooling units for increased temperature
Increasing calendering temperature leads to benefits such as improved quality and
possibility for speed increase. In order to increase the process temperatures of the
calender, new heating-cooling unit is installed (Fig. 21) or the existing unit is rebuilt.
Water or oil is used for heating. Even and safe temperature control can be achieved
with controlled heating and cooling phases.

Fig. 21 Heating-cooling units for increased temperature

2.3.5 Digital hydraulics for calender rebuilds3)

Digital hydraulics control is excellent way to rebuild calender loading system.
Traditional hydraulic cylinders have been controlled with proportional valves, which
requires a relatively large hydraulic unit running at all times due to an internal leakage
of the proportional valves. On the other hand, in digital hydraulics control, an
accumulator and sufficient number of parallel-connected two-way on/off valves are used
(Fig. 22). There is no leakage of oil with the valves. In addition, during the force
control, the oil flow needed is very small and because of that there is no need for the
hydraulic unit to run at all times. So, digital hydraulics makes it possible to save large
amount of electricity consumption. Measured electrical energy saving during four-week
test period was as much as 98.6 %. And, hydraulic pumps were run only some minutes
per day.
Fig. 22 Traditional proportional valve (left) and digital hydraulic valve (right)

The accuracy in control for nip closing is within 0.1 mm difference in ts/ds. In this type
of control, compact and small hydraulic unit can be located very close to calender on
machine level (Fig. 23).

Fig. 23 Comparison between traditional and digital hydraulic units

3. Conclusion
In recent years, calendering technologies for achieving more efficient, cost effective,
energy and material saving productions are required. In this paper, three major topics
for calenders were introduced.

Aqua cooling technology is an innovative cooling method, in which the combined use of
water spraying to the web and the quick and efficient evaporation of water lowers web
 temperature to a large extent. The combined use of Aqua cooling and hot calendering
that makes it possible to attain a target smoothness keeping elasticity of the inside of
the web to save bulk is attracting attention as a high bulk calendering technology.

OptiCalender Compact enables customers to reduce the investment and operation costs
greatly due to simplified specification.

Regarding machine calender rebuilds, we can propose different menu such as reduction
in number of rolls, improvement of profiles, efficient tail threading, increase in process
temperature, and/or electrical energy saving due to innovative digital hydraulics
depending on customers’ requirements.

It is expected that these technologies are applied for calendering webs in accordance with
the production requirements, showing the effectiveness.

Reference
1) For example, J.A. Bristow, Svensk Papperstidn, 70(19), 623 (1967): D.Eklund, P.
Salminen, Appita, 40 (5), 1986
2) L.N. Salmen, E.L. Back, Tappi, 65, s.107 (1982)：E.L. Back, SHW-Kalander Seminar
in Konigsbronn March 25, 1988
3) Valmet K.K., Energy saving in calenders with digital hydraulics (in Japanese),
Japanese Journal of Paper Technology, 57 (3), 17 (2014)

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