Moving forward together - Liansheng Pulp & Paper's greenfield investment in Zhangpu

Valmet’s long cooperation and partnership with Liansheng Pulp and Paper, which extends almost two decades, reached a new milestone through the start-up of their Zhangpu site phase 1 project in the spring of 2023. The project continues the companies’ long collaboration. Previously, there have been deliveries of corrugated paper line PM 3 to the Changtai site and PM 5, PM 6 and PM 10 corrugated paper and liner board lines to the Longhai site. Extensive and reliable technology by Valmet, including maintenance services, automation systems, flow control and Industrial Internet applications, is enabling Liansheng to transition into new markets with the phase 1 project deliveries.

“We’ve always recognized Valmet’s innovative spirit. The production lines they’ve supplied are environmentally efficient and have low operating costs, and our user experience has been excellent. So when we were looking for partners for BCTMP, cartonboard, high-grade fine paper and tissue paper at the Zhangpu base, Valmet’s competent global expert network, as well as their continuous innovation, made them by far the best choice,” concludes Xue Rongjun, General Manager of Liansheng Pulp and Paper (Zhangzhou) Co., Ltd.

Both teams work one step at a time together to achieve excellent results

Achieving a successful start-up for a project of this magnitude and scale is not easy. With the joint effort of both Liansheng and Valmet teams, all the production lines were started up in two months, with great success and results. Whether it’s equipment supply, factory construction, staffing or equipment installation, all aspects of the project need to run on schedule, and any problems must be solved quickly. The collaboration between the two companies ensured success.

With the joint effort of both Liansheng and Valmet teams, all the production lines were tarted up in two months.

Huang Ju, General Manager of Industrial paper division, Liansheng Pulp and Paper (Zhangzhou) Co., Ltd., proudly states that the cooperation between Liansheng and Valmet at the Zhangpu base has achieved industry-recognized success, which is a significant achievement in Liansheng’s development. “It’s been a big success – no question! Not only do I think it’s successful, but everyone at Liansheng and our customers think the project has been very successful. It wasn’t expected that Liansheng would be able to produce qualified products so quickly – and that we’d even exceed the customer’s expectations of entering the market.”

“Valmet’s technical team is really knowledgeable. Their experts are always willing to listen to our customers’ needs and suggestions, and they offer support quickly. It’s one of the main reasons why we always choose and trust Valmet,” says Liu Shichao, project manager of the Liansheng Pulp and Paper (Zhangzhou) Tissue Paper Project.

Zheng Fenglin, Vice General Manager of Fine Paper, Liansheng Pulp and Paper (Zhangzhou) Co., Ltd., recalls many emotions from the past two years: “With the domestic and international environment, and assembly and logistics issues, this project had its challenges, but neither Valmet nor Liansheng’s project department gave up. We had daily meetings to track progress and arrange work according to the installation and commissioning plan. Although we’ve encountered many difficulties, they haven’t hindered our cooperation.”

Clean and high-bulk pulp ensure excellent cartonboard and fine paper quality

The pulp is used extensively, not only to increase the BCTMP content in the mill’s varieties of white cartonboard, but also for fine paper production. The BCTMP helps increase bulk and the stability of the paper quality, while providing important cost advantages by replacing chemical pulp on cartonboard line PM 1 and high-grade fine paper line PM 3.

Adding mechanical pulp to fine paper is an important way to improve bulk. Zheng Fenglin is very satisfied with the papermaking effect of adding a high proportion of mechanical pulp: “The uniformity of our base paper is excellent because we use BCTMP. Our base paper BCTMP amount has reached new heights in the industry, contributing greatly to our profitability.”

“At the PM 1 cartonboard line, we can achieve a bulk of over 1.63 cm3/g, which gives us a big advantage. Customer feedback is also very positive about our flatness,” concludes Huang Ju.

Having a single technology supplier for the entire production process is a significant benefit.

The additional washing of the BCTMP not only takes the pulp’s cleanliness to new heights but also makes a big contribution to the products’ uniformity and whiteness. “The quality of our fine paper is the biggest advantage. In the early stage of the start-up, customers were very satisfied with our base paper’s uniformity, even twosidedness and smoothness. Those are the best features. The formation in both the high brightness paper and the xerographic copy paper is also excellent for the industry,” says Zheng Fenglin.

Expanding from industrial paper to tissue paper production

Liansheng Pulp and Paper, although a relatively new player in the market, is unafraid of the complex global economic challenges facing the pulp and paper industry. As part of the Zhangpu phase 1 project, they expanded their business further by starting up two Valmet tissue paper production lines, TM 3 and TM 4, with an annual production capacity of 120,000 tonnes.

Sempo, Liansheng’s tissue paper brand, represents the true essence of integrated development in forestry, pulp and paper, emphasizing a commitment to the circular economy. According to Fan Lele, Vice General Manager of Sales of Liansheng Tissue Paper at Liansheng Pulp & Paper (Zhangzhou), the main responsibility of Liansheng’s integrated approach to forestry and pulp and paper production is to ensure a stable supply of raw materials. Based on Valmet’s advanced technology, comprehensive services offering and automation solutions, Liansheng chose Valmet as their partner. The collaboration has worked seamlessly for years, starting with the Jiaomei mill and continuing now with the investment in the Zhangpu mill. Starting from scratch, they have together successfully made a breakthrough in the tissue paper segment.

“In recent months, Valmet’s Advantage DCT200HS tissue machines have been running very stably and are easy to operate. This is particularly valuable for Liansheng’s new factory start-up and our new employees.

The quality, operating efficiency and energy consumption of low-grammage and high-bulk tissue paper are all in line with expectations,” says Zhang Hua, Vice General Manager of Liansheng Pulp and Paper Zhangpu Mill Tissue Paper.

Extensive automation brings total efficiency

Both PM 1 and PM 3 are equipped with an extensive automation package from Valmet, including Machine controls (MCS), Quality Controls (QCS), Profilers, Condition Monitoring, Machine Vision and additional Analyzers on PM 3. The automation system has proven critical for monitoring and maintaining product quality, as well as production efficiency.

Huang Ju believes the significant advantage of Valmet’s ability to deliver both the technology and automation for the entire production process is the key to maintaining stable quality. “Having a single technology supplier for the entire production process significantly enhances the staff’s ability to work, reduces their need to adapt and increases operational stability.”

Zheng Fenglin strongly agrees: “The processing of raw materials, automated approach flow, paper machines, winding, packaging and other equipment are all on the same automation platform, resulting in benefits for resource sharing and optimization. The control of such a wide paper machine would be a challenge for any manufacturer, but when the equipment and automation systems are from the same supplier, it’s easy to optimize, balance and coordinate.”

“If we used three different systems, we would need three operators. Now, with MCS, QCS and Machine condition monitoring under one Valmet DNA frame, we only need one operator. This is a great manpower saving, especially in the current situation, when the paper mill is facing recruiting challenges. Besides, the operation is also more efficient,” says Liu Mingchao, Automation Manager for BM 1.

Intelligent valves help build a smart mill

In the complex pulp and papermaking production process, precise flow control is key to ensuring the production process’s stability and efficiency. This involves key parameters such as pulp consistency and fiber dispersion, and the flow control performance requirements for valves are extremely strict.

Across Liansheng’s Zhangpu site, Valmet’s Neles™ valve series is the trusted choice for all important production areas, including the steam and condensate systems, stock preparation, and other key applications. Neles valves ensure the system’s efficient operation. In areas of pulp production that involve corrosive and erosive flow material, Neles valves provide reliable flow control.

“Throughout Liansheng’s processes, Neles products have performed well and are the only products with a very low failure rate. Liansheng confidently chooses Neles valves because the products have shown excellent performance and reliability. This trust is verified in actual use, providing the mill with an efficient, smooth and stable operating environment, making Neles valves an indispensable and important part of Liansheng’s operations,” says Liu Mingchao.

Future cooperation continues to deepen

With the production of various types of paper at Liansheng’s Zhangpu base, the company has ushered in a new era of product diversification, further enhancing their corporate image and product competitiveness. With the commissioning of the first phase of the Zhangpu project and the start of the second phase, Liansheng will significantly reduce transportation and raw material costs due to its regional advantages. The commissioning of the second phase of the project and the strong complementary product combination also make the company’s integrated “forest-pulp-paper” products more competitive.

Liansheng recently placed repeat orders with Valmet for the second phase of their Zhangpu project for a coated board making line (BM 2) with related automation systems, bleached chemi-thermomechanical pulp (BCTMP) technology and two small tissue machines (TM 5 and TM 6). In addition, Valmet is to supply four tissue machine headboxes for tissue machines TM 7, TM 8, TM 9 and TM 10 on the same site.

We’ve highly valued Valmet for over more than a decade of cooperation.

Commenting on the decision to choose Valmet again, Huang Ju says: “All the products Valmet has supplied us have exceeded our expectations – whether it’s BCTMP, fine paper, cartonboard or tissue paper production lines, everything’s reached the design output, cost and quality requirements. In quality especially, downstream users’ evaluations have been very positive, and market competitiveness is excellent, as are the maturity and stability of Valmet’s equipment. There have been no major equipment accidents from start-up to now, and no major technical modifications in the process. This means we get the continuous and stable products we need.”

“We’ve highly valued Valmet over more than a decade of cooperation. From our operators at Liansheng to the company’s management and its highest decision-making level, everyone thinks Valmet has proven technology and is very reliable. So Valmet will continue to be our preferred choice as the Zhangpu project’s second phase begins,” Huang Ju concludes.

TEXT: Silvia Xi, Bert Xue, Jeanne Ye, Elsa Sinjaga, Anna Boström Mora, Åsa Arencrantz, Kati Tattari