Voith highest-performing glass non-woven production line starts up at Owens Corning’s Fort Smith plant also in news Voith delivers successful emergency support for Caesar Pac.
Highest-performing glass non-woven production line starts up at Owens Corning’s Fort Smith plant
- World’s widest glass non-woven line begins production in Fort Smith, Arkansas
- The line is already running at a speed of around 300 m/min two months ahead of the target date
- The successful implementation is based on a strong partnership between Voith and Owens Corning
Owens Corning, a global residential and commercial building products leader, has signed the takeover document for its new Fort Smith glass non-woven production line. This means the world’s highest-performing non-woven line is now in production. The machine includes the most extensive layout Voith has ever created for a glass non-woven production line. The scope of delivery includes the forming, binding and drying sections.
The technological highlights include the world’s largest inclined wire former HydroFormer, the FiberDry glass mat dryer and a comprehensive Papermaking 4.0 and automation package to increase efficiency, product quality and machine availability. Voith also supplied two IntensaPulper machines based on the Process Line Package (PLP) concept, which has set industry standards in the field of pulping with its energy-efficient technology. The HydroFormer covers a width of 5.5 meters and enables exceptionally uniform forming of fibers up to 40 mm in length with extremely low stock consistency. Sustainability and efficiency were important factors for Owens Corning when deciding on the individual components. The design speed of the line is 510 m/min, which will enable the production of 90,000 tons of glass nonwovens per year. Already two months before the target date, the line is achieving a speed of around 300 m/min.
Success based on a trusting partnership
This success lies in a strong partnership between Owens Corning and Voith from the start of the project through the takeover. Both teams focused on finding solutions and moving forward using a goal-oriented approach.
“The start-up of the glass non-woven production line in Fort Smith is a huge milestone for us. Our customers expect high-quality, consistent products that are delivered on time. This new facility is best-in-class and employs highly sustainable practices that are the result of strong partnerships,” says Rachel Marcon, Vice President of non-wovens business at Owens Corning. “The fact that we can now produce at a speed of 300 m/min has been a positive outcome and shows the success of the trusting partnership between both teams.”
“We are proud that this project can demonstrate our expertise as the leading global full-line supplier. Not only did we deliver customized solutions according to Owens Corning’s specific requirements, but we also provided the customer with intensive support until the machine was successfully taken over and beyond – a truly unique selling point for Voith,” says Guenter Meuser, Senior Project Manager at Voith Paper.
Voith delivers successful emergency support for Caesar Pac
- Emergency assistance from Voith within 24 hours
- Increased dryness after the main press by 0.45 percent, saving 19 kWh of energy
- Successful installation demonstrates Voith’s commitment to excellence and customer satisfaction
Caesar Pac, a leading international company based in Kuwait, recently received critical emergency assistance from Voith within 24 hours. This collaboration shows the strength of the Voith sales and service teams and its commitment to support customers in times of urgent need.
“We would like to extend our deepest gratitude for your efficient response to Caesar Pac’s emergency call. Your prompt action in dispatching a technical team for inspection and measurement, followed by a dedicated online meeting to redesign the roll cover, was exemplary,” says Hamdy Badawy, Production Manager at Caesar Pac International. An onsite troubleshooting session was conducted on short notice, and an in-depth audit and report about the findings was carried out.
“The primary aim of the support was to identify the cause of damage to the fourth press bottom roll and to develop solutions to prevent further issues,” says Rafael Bach, Trouble Shooting Expert at Voith Paper. The analysis identified an unsuitable roll cover build-up, inconsistencies in nip load, and hydraulic system failures. To address these issues, it was recommended to replace the S-Roll cover, verify alignment and nip conditions following structural adjustments, and transition to operating with a single motor. “The team’s expertise in measurement and analysis, combined with the use of cutting-edge tools, has provided valuable insights into our press section. Notably, the project achieved significant energy savings of 19 kWh and enabled us to operate with a single motor instead of two, streamlining our operations,” explains Hussain Abdelhamid, Maintenance Manager at Caesar Pac.
The team suggested using Voith’s ArcticPress design for the S-Roll cover, performing a doctor system audit and improving felt designs to enhance machine efficiency and boost production rates. Several rolls were serviced and/or recovered by Voith with new designs from its press roll cover specialist. “This innovative approach has optimized our spare parts and asset management, leading to enhanced efficiency. Furthermore, the new design improved the overall moisture content after the press section, increasing specific moisture removal through the main press by 0.45 percent,” says Abdelhamid.
An ArcticPress cover, known for its exceptional impact and abrasion resistance, was already installed. “This roll cover features an optimized functional layer, extending its service life and ensuring long grinding intervals while maintaining a consistent profile, press nip and dewatering conditions. The innovative cover structure allows for better energy absorption of the nip forces,” explains Mario Neumann, Application Manager Press at Voith Paper.
“Voith’s efforts to expedite flight shipping of the roll to Europe and the successful installation demonstrate its commitment to excellence and customer satisfaction. We are truly impressed by Voith’s professionalism and commitment to keeping customer business at an excellent level and pursuing continuity as a goal,” confirms Badawy.
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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