Reference: SCA, Mannheim / Germany. SCA Mannheim: expansion joint from Frenzelit eliminates the risk of fire and increases productivity.

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1 Reference: SCA, Mannheim / Germany SCA Mannheim: expansion joint from Frenzelit eliminates the risk of fire and increases productivity. Gaskets Technical textiles Expansion joints Insulation New materials

Paper production Frenzelit expansion joints optimise production at SCA: Higher productivity, lower costs The paper machine WM 4 is enormous.

Each reel is almost six metres wide and weights about 5 tonnes, while the paper web travels through the machine at a speed of up to 1 800 m/min. Leaky: patching of the old bellows seams. requirements.

New leaks, from which steam at a temperature of 470 C escaped at a pressure level of 60 mbar under normal operating conditions, had to be plugged on regular occasions.

2 Paper production Frenzelit expansion joints optimise production at SCA: Higher productivity, lower costs The paper machine WM 4 is enormous. It makes tissue paper for toilet paper production at the SCA mill in Mannheim / Germany (ZEWA!). Its output today: three reels of tissue paper per hour. Each reel is almost six metres wide and weights about 5 tonnes, while the paper web travels through the machine at a speed of up to m/min. Leaky: patching of the old bellows seams. requirements. Regular patching from the outside and the inside produced just as unsatisfactory results as attempts to find design solutions. New leaks, from which steam at a temperature of 470 C escaped at a pressure level of 60 mbar under normal operating conditions, had to be plugged on regular occasions. The biggest problem was, however, that the paper dust consisting of pulp fibres was deposited all over the hood and was set on fire by the leaks. The consequence of these smouldering fires were production interruptions and machine stoppages. The leaks also led to an increase in Yankee hood energy consumption. Old metal expansion joint with leaky flexible jacketing. The machine, which was built in 1980, originally had sliding gaskets in the area of the large, high-performance drying hood, which led to high costs as well as great problems. Attempts to eliminate both with metal bellows expansion joints proved to be unsuccessful as soon as they were installed. The four metal expansion joints with a cross section of 2 by 2.17 meters with the purpose to compensate the axial and lateral movements between the combustion chamber and the drying unit, were unable to satisfy these Strong partnership for effective problem solution: (from left to right) Alexander Clarius (Frenzelit), Reinhold Heinsch (SCA) and Ulf Pöhlmann (Frenzelit).

End of the makeshift arrangements To improve the situation on the WM 4, the maximum hood temperature was reduced, which at the same

Something needed to be done! Installation in cramped conditions.

the problem could not be solved with a metal expansion joint.

3 End of the makeshift arrangements To improve the situation on the WM 4, the maximum hood temperature was reduced, which at the same time reduced the machine production output, however. Maintenance Manager Reinhold Heinsch: A situation that was not acceptable. Something needed to be done! Installation in cramped conditions. Flexible expansion joint the solution It was soon clear to Project Manager Ulf Pöhlmann from the Frenzelit expansion joint division: the problem could not be solved with a metal expansion joint. Only a special flexible expansion joint with efficient heat insulation facilities could meet the special requirements under the unfavourable technical installation conditions. Do you have any questions about your application? Phone: expansion-joints@frenzelit.de

An investment that pays for itself When SCA put the machine back into operation, it was immediately obvious: the leakage problems had been solved.

The Frenzelit application engineers developed the concept for a solution on the basis of the exact requirement profiles and then planned, designed and built four flexible expansion joints with an

In a tight schedule of just three days, the old expansion joints were removed by a specialised company under Frenzelit s supervision and the new ones were fitted.

there has not been a single fire alarm because of leaks ever since. The expansion joints have kept the promises they made, with the result that energy consumption has dropped.

4 An investment that pays for itself When SCA put the machine back into operation, it was immediately obvious: the leakage problems had been solved. And the company s satisfaction has in actual fact increased. For more than one good reason: Many tonnes are moved at the press of a button: tissue production control centre. The Frenzelit application engineers developed the concept for a solution on the basis of the exact requirement profiles and then planned, designed and built four flexible expansion joints with an easily cleaned outer surface that acted as an expansion joint and heat insulation at the same time. Only two-and-a-half months had gone by in the meantime since the inquiry was received. In a tight schedule of just three days, the old expansion joints were removed by a specialised company under Frenzelit s supervision and the new ones were fitted. An extremely tricky job in view of the cramped conditions and the huge dimensions of the new expansion joints. 5 tonnes on the hook: enough paper for about rolls of toilet paper. there has not been a single fire alarm because of leaks ever since. The expansion joints have kept the promises they made, with the result that energy consumption has dropped. It has been possible to increase the operating temperature back up to 470 C, so that the production speed of the machine has been raised to up to m/min. due to the drying capacity that is now available. A smooth drying process with lower costs and higher productivity therefore the investment costs for the new technology were paid back after six months only! On-site check, results as expected: everything fine! Quiet, air-conditioned and dust-free: control centre of the tissue machine.

Frenzelit product range Gaskets and gasket material Comprehensive know-how acquired over a period of many years and process engineering skills enable Frenzelit to set new standards in the production

5 Frenzelit product range Gaskets and gasket material Comprehensive know-how acquired over a period of many years and process engineering skills enable Frenzelit to set new standards in the production of new sealing materials. Frenzelit supplies a complete range of gaskets, with novaphit, the generation of gaskets made from pure graphite reinforced with expanded metal, the material concept novatec engineered graphite with Kevlar (a trademark registered by DuPont), the high-pressure gasket material novapress, the PTFE gaskets novaflon and the metal, dispenser and screen printing gaskets novaform. Technical textiles Skills in the development and processing of highly temperature-resistant fibres combined with decades of experience have made Frenzelit one of the leading manufacturers of technical textiles. The range of sealing and insulating materials consists of various product lines such as isoglas, isotherm, novatex, novaseal and isokeram with different temperature limits up to C. Expansion joints More than forty years of experience go into the production of our fabric and elastomer expansion joints for power engineering and plant manufacturing applications. Due to the extremely exacting demands made in operation, exclusive use is made of highest-quality special woven fabrics produced inhouse from glass, ceramic or aramide fibres as well as the necessary coatings. PTFE composite material and PTFE, rubber and metal expansion joints round off the product range. Insulation The insulation range includes not only heat insulation materials such as woven fabrics, woven tapes and nonwoven fabrics from the isoglas and isotherm product lines but also isoplan insulation panels and special materials for transport rollers used in high-temperature applications, novaplan heat shielding materials and cushioning materials for acoustic insulation. New materials Frenzelit develops and produces a range of high-performance nonwoven materials under the name HICOTEC. These materials are based on use of such high-performance fibres as carbon fibres. They have different properties from both technical textiles and high-performance papers. They are new materials for new application areas.

6 expansion joint for sca technical data Temperature: max. 480 C Movement: axial up to 30 mm lateral 250/60 mm Daily start-up and shutdown possible Internal dimensions: x mm Installation height: mm Yes, we are interested in expansion joints. Please send us the following, with no commitment for us: Detailed information material Fabric and Elastomer Metal Rubber Please arrange an appointment with us. Surname, first name Company Street reply Postcode, town/city Country Telephone/fax Frenzelit-Werke GmbH & Co. KG P.O. Box Bad Berneck Germany

7 Thanks to prestressing, the new expansion joints cope with axial movements of up to 30 mm and lateral movements of up to 250 mm without any difficulty. advantages at a glance: safety aspects: No danger caused by hot air from leaks No risk of fire working conditions: Bearable temperatures during cleaning Greater safety More room to move economic aspects: Higher productivity Lower energy consumption maintenance aspects: More convenient maintenance Longer maintenance intervals Better availability

solution partners reinhold heinsch, maintenance manager, sca hygiene products Gmbh, mannheim mill: ulf pöhlmann, sales manager of the Frenzelit expansion joint division: achim schmittel, wm 4 machine

Firstly, it is more pleasant: we can operate at higher temperatures but have substantially lower temperatures when cleaning the machine every day since there are no leaks with the new solution.

Figures data facts The Frenzelit solution that we have now installed was not just the only conceivable one; it was also the only correct one.

SCA Tissue Europe is the leading tissue supplier in Europe. The heaquarters of the business unit is in Munich / Germany.

8 solution partners reinhold heinsch, maintenance manager, sca hygiene products Gmbh, mannheim mill: ulf pöhlmann, sales manager of the Frenzelit expansion joint division: achim schmittel, wm 4 machine operator, sca hygiene products Gmbh, mannheim mill: The new expansion joints have improved our working conditions considerably. Firstly, it is more pleasant: we can operate at higher temperatures but have substantially lower temperatures when cleaning the machine every day since there are no leaks with the new solution. Secondly, it is safer we have not had a single fire any more since the change was made. Figures data facts The Frenzelit solution that we have now installed was not just the only conceivable one; it was also the only correct one. The WM 4 is not a problem for the maintenance department any more. The risk of fire has been eliminated, productivity has been increased and operation is no longer interrupted by leaks. SCA Tissue Europe is the leading tissue supplier in Europe. The heaquarters of the business unit is in Munich / Germany. The product range consists of toilet paper, folded towels and household towels, napkins and paper handkerchiefs. SCA Tissue Europe s customers include major international retail chains, industry, service companies and the retail trade. SCA s most well-known brands include Tork, Tempo, Zewa, Velvet and Edet in addition to a wide range of own-label brands that are well-established on the European market. SCA Tissue Europe is a business division of the Swedish SCA Group, has about employees and generated sales of about EUR 2 billion in alexander clarius, application advisory/sales department of the Frenzelit expansion joint division: High-performance expansion joints are not available off-the-peg when replacements are required. The advantage of this is that we do not sell what we already have; instead of this, we develop customised products which exactly fit to your needs. We can solve (almost) any problem thanks to our lengthy experience and our in-depth production operations. We provide comprehensive service to our customers. From on-site analysis of the problems to concept development and planning, construction, assembly, monitoring and maintenance. HS/1/03.08/01/WY Subject to technical amendment. Gaskets technical textiles expansion joints insulation new materials Frenzelit-Werke GmbH & Co. KG P.O. Box Bad Berneck Germany Phone: Fax: info@frenzelit.de

GASKETS TECHNICAL TEXTILES EXPANSION JOINTS INSULATION

GASKETS TECHNICAL TEXTILES EXPANSION JOINTS INSULATION new MATERIALS At home in all industries. Creating hightech solutions. GASKETS TECHNICAL TEXTILES EXPANSION JOINTS INSULATION NEW MATERIALS Frenzelit