Improve your paper machine with well planned rebuild

Paper machine rebuilds offer ways to remove production bottlenecks, reduce production costs, improve operating safety, save energy, or add new grades with paper machine conversion. A rebuild involves rebuilding parts of a paper or board machine using different components with the aim of improving the process or end products. Valmet has the right tools for paper machine rebuilds, including experience and expertise so you can meet your targets for the rebuild.

New machines vs Rebuilds

If you have the choice between buying and rebuilding an old paper machine to your specifications or building a brand new machine, what should you consider?

The basic rule of thumb is that a rebuild will always be much more demanding than new installation. An old machine, even if it’s only 10 years old, comes with limitations. It will take more time, money and engineering to ensure that the old and new components work well together. Meeting the start-up curve will take longer time. Conversely, a new machine is a pre-tested whole that is designed to work in unison.

A rebuild involves rebuilding parts of a paper or board machine using different components with the aim of improving the process or end products. Rebuilds can improve productivity, quality and efficiency, and they can enable you to produce different grades. They can also help your company reach strategic business goals, including measures to improve market position, to meet new market needs or to match a competitor’s capacity and/or quality. In the current market, common rebuilds are grade conversions of printing and writing paper machines.

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Why consider a Rebuild?

Rebuilds can improve productivity, quality and efficiency, and they can enable you to produce different grades. They can also help your company reach strategic business goals, including measures to improve market position, to meet new market needs or to match a competitor’s capacity and/or quality. In the current market, common rebuilds are conversions of printing and writing paper machines.

It is worth ensuring that the technical and process goals of a proposed rebuild will also meet the business goals. The good news is that whatever the requirement, there are many options and possibilities to improve both your machine and your business.

How to plan a successful rebuild?

Rebuilding a paper or board machine can improve the competitiveness of your business and your processes. But where do you start? Download our e-book to learn how to develop a winning rebuild concept, how to minimize rebuild related risks, and how to ensure smooth ramp up to full production.

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Nippon Dynawave: sustainable board with less CO2 emissions and fibers

Oct 10, 2022

Nippon Dynawave wanted to go towards a more sustainable board production. They succeeded in reducing greenhouse gas emissions and using less fibers for the same amount of board with the Valmet-supplied metal belt calender.

Customer's voice: Dilution control headbox reduced grammage deviation and improved paper strength

Oct 17, 2021

"Just plug and play, start the systems, and get extraordinary good quality out of the PM34." , said Thomas Gehring, Mill manager at Ahlstrom-Munksjö Dettingen Mill after successfull wet end rebuild of their PM34.

ITC Bhadrachalam BM1 coated board machine in India for sustainable packaging

May 22, 2020

Valmet supplied ITC an extensive board machine rebuild and automation solution for machine and quality control. The coated board they produce (FBB) has important role in replacing plastics and there is an increasing demand for packaging board in India.

Sappi Maastricht: new 3-layer headbox and metal belt calender for extremely good board quality

Mar 7, 2020

Sappi Maastricht mill in the Netherlands got a new future for its board machine with Valmet’s innovative three-layer headbox and metal belt calender. They are now in the specialty boards business producing extremely high-quality SBS and FBB with superior smoothness and printability.

Paper coating process optimization brings savings at Cartiere del Garda

Aug 2, 2019

A rebuild of air dyers with new Valmet nozzles on Cartiere del Garda’s off-line coating machine in Italy has increased speed, reduced energy consumption and improved web stability. On top of everything, they can now guarantee their printing paper customers better quality – even on lighter grades.

New off-line coating machine at SAICA El Burgo

Mar 25, 2019

A beautiful story of partnership to develop completely novel and innovative coated white top liner grades. Valmet supplied a new off-line coating machine at SAICA El Burgo in Zaragoza, Spain, where curtain coating head plays a key role.

Energy-efficient air drying at SAICA, El Burgo

Mar 25, 2019

Safety played a key role when SAICA El Burgo in Zaragoza, Spain, chose air drying technology for their new, Valmet-supplied off-line coating machine. High coating quality proved at pilot trials and energy savings compared to IR dryers were also important.

Successful conversion from paper to board – Stora Enso Varkaus PM3

Sep 15, 2017

From Paper to packaging – Stora Enso’s Varkaus mill in Finland converted their existing paper machine into a board machine to produce linerboard in 2015. They chose Valmet as their partner for this challenging rebuild. The successful conversion from paper to board has been a marvelous journey to better meet the market need for renewable packaging.

Read our latest customer success stories about Valmet delivered rebuilds

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Questions and answers about replacing gas with electricity in coating drying

Jun 7, 2023

Many paper makers are considering replacing gas with electricity in coating drying. To make you feel more secure with the change, we have answered frequently asked questions about replacing gas with electricity and infra-red dryers with air dryers.

Asia Paper Manufacturing uses OptiSizer Hard to improve board strength

Jan 2, 2023

Asia Paper Manufacturing in the Republic of Korea had an ambitious target to improve the board strength values. They invested in OptiSizer Hard. Compared to conventional sizers, it pushes starch deeper into the board web improving the overall strength values.

Ranheim Paper & Board invested in an efficient heat recovery system leading to 14% savings in energy consumption

Nov 30, 2022

Cold working environment and quality issues led Ranheim Paper & Board to invest in Valmet’s heat recovery system OptiAir Recovery. As a result, the mill achieved savings in energy and a significant increase in production.

Sustainable board production with less CO2 emissions and fibers at Nippon Dynawave Packaging

Sep 21, 2022

Learn how the partnership between Nippon Dynawave Packaging and Valmet has resulted in increased flexibility, boosted efficiency and enhanced quality at the mill.

Exceeding expectations with OptiAir Recovery mist remediation at Ajin P&P's PM 2

May 10, 2022

In 2019, Ajin P&P decided to rebuild its paper machine PM 2 with a target to increase the mill’s production and improve the end-product quality. The rebuild was delivered by Valmet and it included OptiAir Recovery mist remediation to reduce and eliminate mist and enable the increase of heat recovery capacity.

Shutting down safely at Blue Paper

Dec 21, 2021

In November 2020, Blue Paper launched the “Vulcan” project by modernizing its paper machine dryer section to increase its capacity and performed various maintenance tasks. During the six-week shutdown, the safety of everyone was secured despite the ongoing pandemic.

A new start with an OCC grade conversion at Burgo Verzuolo PM 9

Nov 2, 2021

In 2020, Burgo's Verzuolo converted their existing paper machine to OCC board grades. This meant high-quality grades with minimal virgin fibers and low operating costs. Everyone involved was very pleased with the results.

Rebuilding for better packaging

Oct 28, 2021

“A company that makes the world beautiful” with packaging – Ajin P&P’s slogan becomes even more true now that the company’s smart factory plan has just been approved by the Korean government.

What do you want to achieve with your rebuild?

There are many options and possibilities on how to improve both your machine and your business through a rebuild. Read more about these options below.