At the time of this installation, Mayr-Melnhof Baiersbronn (now part of FOLBB Group) produced high-quality virgin-fibre paperboard on production lines equipped with two sheeters. Their existing first-generation web cleaning equipment had reached the point where replacement was required.
The project focused not only on cleaning performance, but also on reducing energy consumption, lowering noise levels, simplifying maintenance and improving accessibility for operators.
Mayr-Melnhof wanted to evaluate whether developments in non-contact web cleaning technology could provide better cleaning performance while reducing the operational demands of the existing installation.
Performance, energy use and operator requirements
Selecting a replacement web cleaning system required more than comparing cleaning performance alone. The new installation also needed to fit within the existing production environment, reduce energy use and noise, and simplify operation and maintenance.
Following installation of the Weducon system, energy consumption was reduced by 50% compared with the previous web cleaning installation. Operating noise did not exceed 83 dB.
A follow-up from the production team shortly after commissioning also showed that the amount of dust removed by the new system exceeded expectations.
Read the follow-up customer feedback and observed dust removal results.
Requirements for the new web cleaning system
Before designing the new installation, Weducon and Mayr-Melnhof evaluated the complete working environment:
- How much installation space was available?
- Could more working space be created around the production lines?
- Could web threading and other operator tasks be simplified?
- Could the web cleaning system be automated?
- Could the use of consumables and spare parts be reduced?
- Could regular maintenance be simplified compared with the previous equipment?
In addition to effective web cleaning, the new system therefore needed to be maintenance-friendly, operator-friendly and compact.
Weducon HE-90 web cleaning on two paperboard sheeters
Weducon equipped both sheeters with 2,500 mm wide HE-90 web cleaning systems for a maximum web width of 2,400 mm.
The installation was designed to use the available space efficiently while maintaining clear access for operators.
Web threading remains unobstructed. When the cleaners open for feeding a new web, pneumatic slide valves immediately shut off the airflow. This prevents the vacuum from catching the web and simplifies handling during web changes.
To preserve space around the production lines, the AFI-840 filter/fan unit was installed in an adjacent warehouse. Rigid laser-welded ducting connects both sheeters to the filter/fan unit, following the same route as the existing trim extraction.
Reducing space and energy requirements
The installation was designed around the operating and maintenance requirements of both production lines. Electrical cabinets remain accessible, and mounting brackets are positioned to maintain safe access for operators.
Interfaces between the web cleaning systems and both production lines were included in the installation. Individual switching allows energy use to be reduced when only one production line is operating.
Two operating setpoints control the frequency converter so airflow and power consumption can be matched to the production situation while maintaining the required cleaning performance.
Automated operation and reduced maintenance
Operator functions are automated, including the self-cleaning filter/fan unit and Weducon’s protected 24V DC active ionisation.
Apart from regularly emptying the collected dust, routine maintenance is limited to an annual service carried out by the supplier.
The installation therefore combines non-contact web cleaning with reduced energy consumption, controlled noise levels, automated operation and simplified maintenance.
Learn more about Weducon’s web cleaning solutions for paper and board production, or contact us to discuss your production requirements.
Installation details and context: paperboard web cleaning at Baiersbronn
Client at time of installation: Mayr-Melnhof Frischfaser Baiersbronn, Germany
Current mill: Baiersbronn Frischfaser Karton GmbH, FOLBB Group
Application: Paperboard production / sheeting
Substrate: Virgin-fibre paperboard / solid board
Number of production lines: Two sheeters
Production speed: 300 m/min
Web width: 2,400 mm
Web cleaning system: Weducon HE-90
Web cleaner width: 2,500 mm
Filter/fan unit: Weducon AFI-840
Ionisation: Protected 24V DC active ionisation
Reported energy reduction: 50% compared with the previous web cleaning installation
Operating noise: Maximum 83 dB
Maintenance: Regular dust collection emptying plus annual service
