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MODERNIZING OF WET HARDBOARD PLANTS

PRESS AND THE FIRST PART UP TO THE DEFIBRATOR


The organization of today is as follows:
• From the woodyard to the defibrator is Metso supply.
• The hot press is Sunds MDF Technology AB supply.
• The pulp system, wet forming, feeding system and elevators is Sigma’s supply.
• Second hand equipments is Sigma’s supply.

Normally Sigma does not work with upgrades for the press, that is a question for Sunds MDF Technologies
AB. However we must support and propose solutions for our customer when they start to upgrade the press
with particular parts like:
• More openings.
• Upgrade the hydraulic.
• Upgrading of the hot water system.
• The new sophisticated press curve with better dewatering.

In order to do business it is necessary for Sigma to have complete competence over the whole line and that is
the idea of our organization and corporations.
It is not always so that our corporate partners are involved in a project, but we have the possibilities to sup-
ply all necessary expert information and proposal for solutions.

SIGMA SERVICE AB
As an example Sigma visited a customer some weeks ago and we noticed their long press cycles, they had
already rebuilt the hydraulic and their hot water capacity. We did a quick check to test the new press curve.
(It is a sophisticated automatic control system comprising measuring of the entrapped steam pressure, it
pumps the pressure making it easier for the confined steam to get out).

It was of course not possible to do it in a automatic way. We did it in a manual way and pumped out the
steam in accordance to the principal diagram. The result was with the circumstances, a shorter press cycle
time by 20% (we also increased the temperature with 5 degrees).
In conclusion we believe that this is possible in a number of places, with tests and experiences change the
press curve a little bit in accordance to the new press curve. Also having a simple PLC / HMI system for the
press operation and control.
This also minimizes the operators influence, is easy to change, has a digital history of used press curves. 



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MODERNIZING OF HARD BOARD PLANTS
FEEDINGSYSTEM “supplied by Sigma”
• Double weaved screens.
• Fastening system of screens at the caul plate.
• High-pressure washing of wire screens; in line or off line.
• Mating of wet lap and caul / screen (+-7 mm).
• Wet lap cutter (water jet or mechanical).
• Wet lap Conveyors (see advantages in the flyer).
• Conveyor system that increase the speed and positioning without time production loss (silent and exact
functions)
Consists of:
Charging conveyor; with the charging “The Dog”
Elevators; and the positioning of it.
Pusher / Extractor
Discharge conveyor
Sheet separator.
Cross conveyors.
Return conveyors.
Special conveyors; Service conveyors; Tipples and after press equipments.

SIGMA SERVICE AB
• Control system in synchronization with special frequenzy controlled gear motors. Possible to optimize
all the speed of each conveyor from one terminal!
• Process automation system.
• Frame feeding system.
• Surface plates and Sigma’s grinding and polishing machine for surface plates.

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SIGMA REBUILDING EQUIPMENTS FOR THE
WET FORMING MACHINE
We have developed rebuilding “kits” that could be installed
separately and will also complement each other to reach
further speed, capacity and quality.

The rebuilding sets could be combined in different ways,


depending of the existing condition and what result that is desirable.

The rebuilding sets are based on the Metso rebuilding “kits”


and Sigma has upgrade parts of it and also the installation and use of it.

SIGMA SERVICE AB
It consists of:

• New inlet box, pressurized.


• New inletbox, open type.
• New gravity box. • New complete Press Section of the modern type
• New suction box. with plane press and the effective suction and
• Rebuilding of the upper part of existing suction dewatering.
boxes with a more effective cover and • Complete system for replacement of vacuum
dewatering. pumps against a vacuum fan, with frequency
• New modern hydraulic plane press part, to be control and water separator! (important to design
installed in existing equipments. it for a capacity enough also for a later on in-
• New modern regulated single press roller part, stalled new suction and dewatering part)
with suction who could replace the two exist- • Cleaning systems for wires!
ing press roller parts! (That makes the machine • Wire guides for wet forming machines.
shorter and makes it possible with one additional • PLC / HMI systems for process control of the
storage place for wet lap) wet forming machine.

PULP SYSTEM
Regarding the pulp system we also have some rebuilding and upgrading packages, but in order to propose
something we need information about todays specifications.

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Optimizing Press Performance

If you find that your press capacity is creating a bottleneck in your board operations,
consider letting us find the right solution.
Improvements can generally be made by:

• Increasing the umber of openings. This can sometimes be achieved without


having to change rams and columns.
• Rebuilding the hydraulic system to decrease closing and pressure build-up time.
Energy consumption can also be reduced as a result of this measure.
• Modernizing and automating the loading and unloading sequence, thereby
minimizing dead time.
• Using a newly patented PLC- and HMI controlled press curve (shorter pressing
time and improved quality). Such control system can be installed with no need
for modification of existing hydraulics.

SIGMA SERVICE AB
Heating the press

An important factor in ensuring high capacity utilization of the hot press is flow con-
trol of the heating media. In this area, we can provide you with the best possible solu-
tions for flow control. Through the press and the control of the flow from the hot water
accumulator. Our technical staff will also be able to advise whether your accumulator
can be modified to increase its efficiency. Our expertise will ensure that the variation in
the steam flow from the boiler to the accumulator is minimized. Control of the heating
media flow can also optimize the drying capacity of the hot press. The end result is a
significant increase in throughput capacity and lower costs.

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Modernizing your press
Based on years of experience in rebuilding and modernizing hardboard plants, its now possible to
identify a number of ways to improve the performance of your press operations.
For example:
• We can re-bore worn press cylinders on site. Using mobile re-boring equipment, our skilled
engineers can re-machine and produce a smooth surface for the packing. At the same time we
will install new cylinder and gland liners. Re-boring will lengthen the working lifetime of the
packings and decrease the number of machine stoppages for packing replacements.

• By reconditioning corroded contact surfaces on both the top and press tables and by exchang-
ing worn-out insulation, we can improve the straightness of the tables thus reducing the thick-
ness tolerances of the board. To extend the lifetime of table edges and surface with stainless
material.

• Our rebuilding program also includes providing a more efficient form of insulation between the
heating platens and the top table and press table respectively. This will prevent unacceptable
heat deformation and further improve thickness tolerances in the pressed board.

• When it comes to heating platens we would, of course, recommend the modern Motala longitu-
dinal channel system based on the counterflow principle. This configuration guarantees an even
temperature across the entire surface. Alternatively, we can recondition your existing platens in
our workshops.

SIGMA SERVICE AB
• For production of thicker types of board, we can install a thickness measuring unit to monitor
and control press table position throughout the pressing process. This will efficiently reduce
thickness variations and diminish press cycle time.

• If you are making thick medium-density board, we can supply the necessary pressure equal-
izing equipment to compensate for the weight of the heating platens required.Our latest spring
units for simultaneous closing will improve performance and reduce thickness tolerances.

• Many older press types have heavily corroded columns. Its possible to produce pre-stressed
columns that ensure a substantially extended lifetime. There is also a newly developed design
for the press column function with a stress rod that is pre-stressed in its entire length. The rod
is surrounded by a protective sleeve which also serves as a distance piece between the top table
and the hydraulic cylinders.

• Many old presses, are generously dimensioned and often allow more openings. The limiting
factors to be considered are the length of the columns and the maximum stroke of the cylinders.
Such rebuilds, increasing the capacity by about 10%, have been made in many mills.

• After inspection, our specialists can also suggest other improvements, such as better plate trans-
port guides and stepped uprights.

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