Case Study
Heavy-Duty Mega Packaging Formers — 6.6m Giant Machine Cluster
Hupo Paper / Hubei Rongcheng / Yunnan Dongsheng (6,600 mm Cluster) — China
China
Valmet / Voith Multi-Ply Wire Formers
750 – 1,100 m/min
12 weeks covering 3 machine sites
Project Snapshot
Country
China
Paper Type
70 – 250 g/m² Kraftliner / High-Strength Corrugating Medium
Machine Brand
Valmet / Voith Multi-Ply Wire Formers — 6,600 mm
Machine Speed
750 – 1,100 m/min
Project Duration
12 weeks covering 3 machine sites
Customer Background
A cluster of three 6,600mm giant packaging paper machines operated by three leading Chinese packaging paper groups. These mega multi-ply Fourdrinier formers run on highly abrasive 100% recycled fiber, producing heavy-duty kraftliner and corrugating medium (70–250 g/m²) for domestic and export packaging markets.
The Challenge
The combination of 6.6m ultra-wide format and 100% recycled fiber with extreme abrasiveness placed unprecedented mechanical demands on the fabrics. Fabric changes were required every 35–40 days, creating frequent production interruptions. Multi-ply configuration demanded precise dewatering control to prevent inter-ply delamination. Fabrics had to maintain absolute dimensional stability under continuous high-tension, high-temperature operation.
The Solution
Integrated solution: 3CSSB forming fabric + BGW22608 heavy-duty flat yarn dryer fabric combination. Alternating PET/PA6 abrasion-resistant weft yarns delivering 3–4× wear resistance, with FSI calibrated to each ply's specific basis weight. Dryer fabric equipped with PTFE coating for ash resistance at >12% concentration and enhanced high-temperature dimensional stability.
Root Cause Analysis
Standard double-layer fabrics lacked sufficient structural rigidity for the 6.6m width under continuous high tension with highly abrasive recycled stock. Surface weft yarns were not optimized for sustained ceramic blade contact and ash content exceeding 12%, leading to accelerated surface wear and premature fabric failure.
Implementation Timeline
1
Multi-Site Audit
Weeks 1–3Synchronized audits across 3 machines, stock analysis, wear history compilation
2
Custom Engineering
Weeks 4–6Machine-specific custom configurations, accelerated wear testing
3
Phased Deployment
Weeks 7–11Prioritized sequential installation per machine, parameter calibration
4
Stabilization
Week 12Cross-machine performance comparison and final tuning
Results — Verified KPIs
Fabric life extended from 38 to 58 days (+53%). Inter-ply defects reduced by 62%. Machine availability improved 5.1%. Total cost of ownership reduced by 28% across the three-machine cluster.
| KPI Metric | Before | After | Improvement |
|---|---|---|---|
| TCO | −28% | — | |
| Fabric Life | +53% | — | |
| Availability | +5.1% | — | |
| Interply Defects | −62% | — |
Return on Investment
Fabric life extended 53%. Total cost of ownership reduced 28% across 3 machines. Investment recovered within the first fabric cycle.
“Industrial validation in heavy-duty packaging paper. Taming 6.6m giant multi-ply Fourdrinier formers running on highly abrasive recycled stock”
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