Hinojosa Packaging commissions Voith with comprehensive rebuild of PM 1 in Alquería, Spain, whilst also in news the DS Smith’s rebuild of PM 4 at Viana Paper Mill is successfully completed.
Hinojosa Packaging commissions Voith with comprehensive rebuild of PM 1 in Alquería, Spain
- Rebuild enables an increase in production of around 19 percent to 128,000 tons per year
- Measures also aim to improve overall machine efficiency and reduce steam consumption
- Start-up is scheduled for first quarter of 2026
Hinojosa Packaging Group, a leading Spanish paper manufacturer, is realizing the planned rebuild of its PM 1 at the Alquería site, Spain, together with full-line supplier Voith. The project aims to increase the production of containerboard with basis weights of 115 to 195 g/m² by around 19 percent to 128,000 tons of saleable paper per year, improve overall machine efficiency and reduce steam consumption.
With a strong strategic focus on the circular economy and decarbonization, Hinojosa Packaging Group is committed to innovative production processes. The planned rebuild of the PM 1 with a wire width of 3,400 mm and a design speed of 1,000 m/min is a further step to improve the company’s environmental footprint while ensuring efficient, reliable operations.
“Future-oriented production processes require innovative technologies,” said Juan Jose Calvo, Project Manager at Hinojosa Paper Alquería. “With Voith, we have an experienced partner at our side who is very familiar with the future-oriented transformation of paper machines. We look forward to the collaboration and the results, which will help our company continue producing profitably and in line with sustainability requirements.”
“Efficient, resource-saving technologies are our specialty,” says Ignacio Benito, Head of Applications & Engineering at Voith Paper. “We are very happy that Hinojosa Packaging has placed its trust in our many years of expertise and that we can future-proof PM 1 together.”
The shutdown and restart of PM 1 are scheduled for the first quarter of 2026. The rebuild includes upgrades to both the OCC stock preparation and the paper machine. Voith will make changes to the approach flow system and also relocate the existing headbox. The forming section will be optimized and will receive new dewatering elements. “Innovative modifications in the press section will enable a higher dry content and thus significantly reduce specific energy consumption with increased production capacity,” explains Philip Schnellinger, Process Technology Manager at Voith Paper.
The first dryer group will be converted to a single-tier configuration with DuoStabilizers to enable ropeless threading and better web stabilization. New direct drives (“silent drives”) are planned for the entire dryer section. In addition, new S-Stabilizers will be installed in the double-tier dryer groups of the pre-dryer and after-dryer sections. An additional dryer group with new EvoDry steel drying cylinders will also be installed in the pre-dryer section. Four additional EvoDry steel drying cylinders will be installed in the after-dryer section and the drying hood will be extended.
Voith’s Prevo system will be used to transfer the paper tail quickly and safely from the after-dryer section to the reel. The existing reel will be relocated and equipped with a new reel spool magazine. Voith’s QCS On.Quality system will be integrated to improve process and quality monitoring. An extensive spare parts package as well as comprehensive engineering and services are also part of the scope of supply.
Customers worldwide benefit from Voith’s tailor-made modernization solutions that improve the efficiency, performance and service life of paper production systems. Machine optimizations and rebuilds of varying scope enable a significant reduction in operating costs and increase in production quality without the need to invest in new lines. The order confirms Voith’s proven expertise in customized rebuild solutions and underlines its role as a trusted partner for innovative and sustainable solutions in the paper industry.
About the Hinojosa Packaging Group
Hinojosa Paper Alquería, located in Alquería de Aznar, Alicante, is a part of Hinojosa Packaging Group, a leading company in the design and manufacture of sustainable packaging solutions. With more than 75 years of history, its model is based on the principles of the circular economy.
Thanks to permanent innovation, customer orientation and the pursuit of excellence, the company has continued to grow, experiencing a significant boost in recent years with its commitment to internationalization. Today, it has 2,900 employees and 24 production plants located in Spain, Portugal, France and Italy, combining the strength of a global group with proximity to the territory.
Hinojosa’s commitment – and performance – is to generate a positive impact where it operates, contributing to a greater common well-being. Because it is not only about making the best packaging, but taking care of everything around you.
Rebuild for DS Smith’s PM 4 at Viana Paper Mill successfully completed
- Increased dry content after the press ensures higher energy efficiency and increases sustainability
- New Tandem NipcoFlex press enables 15 percent specific steam savings
- Almost 90 percent fewer paper breaks after rebuild
Following its rebuild and start-up in October 2023, PM 4 at DS Smith’s Viana Paper Mill reached final acceptance. The rebuild has increased production from 400,000 tons to 430,000 tons of kraftliner and high-performance top kraftliner per year, at a design speed of 1,200 m/min. This improves the plant’s overall efficiency and further strengthens its position as market leader in Southern Europe.
The rebuild included modifications of the wire section, a completely new press section and upgrade of web transfer between the press and dryer sections. In addition, modernizations in stock preparation were part of the rebuild. The forming section scope comprised new dewatering elements, a high-pressure water jet edge trim cutter from the Prevo family and a suction reversing roll for the top wire. A new Tandem NipcoFlex press outfitted with QualiFlex Crown sleeves and modifications for the web transfer to the dryer section made up the scope of the press section rebuild. A comprehensive fabrics package including I-Series forming fabrics, Vector and Infinity press felts and Jade dryer fabrics were supplied for the start-up and optimization phase of PM 4, including services and spare parts. With machine safety in focus, the press section was additionally supplied with ProTect, enabling safe and reliable felt profile measurements.
In combination with Voith services and spare parts, the rebuild achieved 15 percent specific steam savings with an increase in production and almost 90 percent fewer paper breaks due to fly-off in the wire section. Driven by sustainability, the rebuild objectives of increasing the overall efficiency and production of the machine at lower energy consumption were fully achieved.
“We are very satisfied with the results achieved. The promised dry contents after the press were achieved for all grades, helping us meet our ‘Now & Next’ decarbonization targets by reducing energy consumption and producing kraftliner more sustainably and efficiently,” said Eduardo Fernandes, Project Manager at DS Smith. “The results after the rebuild speak for themselves,” said Philip Schnellinger, Process Technology Manager at Voith Paper. “Our full-line solutions are having the desired effect on the overall efficiency of the process line and consumption of resources during production. This success was made possible by the selection of the right concept and the close and trustful cooperation between the two teams.”
About the Voith Group
The Voith Group is a global technology company. With its broad portfolio of systems, products, services and digital applications, Voith sets standards in the markets of energy, paper, raw materials and transport & automotive. Founded in 1867, the company today has around 21,000 employees, sales of € 4.9 billion and locations in over 60 countries worldwide and is thus one of the larger family-owned companies in Europe.
The Group Division Voith Paper is part of the Voith Group. As the full-line supplier to the paper industry, it provides the largest range of technologies, services and products on the market and offers paper manufacturers holistic solutions from a single source. The company’s continuous stream of innovations facilitates resource-conserving production and helps customers minimize their carbon footprint. With its leading automation products and digitalization solutions from the Papermaking 4.0 portfolio, Voith offers its customers state-of-the-art digital technologies to improve plant availability and efficiency for all sections of the production process.
Contact: Anna Dennerlein – Vice President Global Communication Voith Paper – Tel. +49 7321 37 9055
Anna.Dennerlein@voith.com – www.voith.com
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