Keep on winding - How to optimize winder performance throughout its lifecycle

Over the years, Valmet has delivered more than 1,000 winders and over 1,500 winder modernizations to its customers worldwide. With this extensive expertise, Valmet can support its customers across every aspect of the winding operation and throughout the whole machine's lifecycle: from start-up to routine maintenance, preventive maintenance, process control, rebuilds and beyond. With Valmet’s experienced winder specialists, mills can consistently achieve their targets for runnability, performance, and paper roll quality.

“We’re here to support our customers over the long-term – for the entire winder lifecycle – combining unmatched expertise with well-proven technology,” says Tatu Pitkänen, Global Technology Manager, Improvement projects and Roll services, Valmet.

Winding for high quality paper rolls

Winder performance has a direct impact on the quality of each paper roll delivered to your customers. Issues such as worn roll surfaces, wrong choice of roll cover for the specific paper grade, outdated technology, incorrect slitter settings, poor mechanical condition or machine cleanliness can quickly lead to quality deviations.

One of the most effective ways to resolve quality issues is to do a detailed inspection of the winder to identify existing or potential problems, and areas for improvement. To help customers with this, Valmet offers a range of winder auditing services, including process and condition tests, capacity audits and safety audits.

Valmet’s Slitter Management Program (SMP) eliminates slitting-related issues by taking full responsibility for slitter grinding and inventory. Customers benefit from unlimited grinding for a fixed fee, consistently high blade quality, and automatic replacement when the slitter reaches its minimum diameter — all handled seamlessly by Valmet.

“The Slitter Management Program offers a one-stop-shop for all customers regardless the original equipment manufacturer or their winder. It significantly reduces maintenance costs while extending slitter blade life and blade-change intervals. This ultimately improves overall slitting performance and customer roll quality,” says Miikka Hyvärinen, Global Technology Manager, Finishing Consumables, Valmet.

Valmet Slitter Holder Quick Change is safer and faster than the conventional change methods. 

Winder drums also play a key role in maintaining production quality, and choosing the right roll cover for the process is essential. Valmet provides high quality soft covers and hard coatings for winding drums in all winding applications.

“Our covers have been carefully developed and tested to deliver good wear resistance, long running times, better runnability and customer roll quality. The iRoll technology offers a possibility to extend the roll’s basic function to be utilized as a tool for winder runnability and customer roll quality optimization tool,” Tatu Pitkänen says.

Drums can be covered with hard coatings on-site, always matching the customer’s product and winder type. For example, Valmet Winder Drum Cover TM and TM-R can be applied to winder drums during shutdowns.

Winder Drum Cover WG and WG-W are high performance soft covers, offering consistency in winding quality with increased productivity. Flexible contact between covered drum and customer roll helps to avoid wrinkling, dishing, paper crushing or noise related issues.

With Valmet winder services, you’re getting unmatched expertise and well-proven technology.”

Maintenance support for operational reliability

To support customers with on-site work, Valmet provides a range of field service packages that cover each part and functionality of the winder. Valmet’s Field Service teams work side by side with the mill personnel to keep the winder running reliably and safely.

“Whatever the customer needs, we have a team that can handle it. Our expertise covers everything from start-ups to troubleshooting at any stage of the equipment lifecycle,” says Ari Linnankoski, Global Product Manager, Performance Parts and Field Services, Valmet.

Valmet’s winder specialists can support customers with all types of maintenance activities, including original Valmet spare parts. With Valmet’s spare parts management service, mills can rely on fast availability of critical components. Customers can also check part availability and machine specific spare parts lists through the ePartsbook service in the Valmet Customer Portal.

We’re committed to giving our customers the best support possible. No question will go unanswered.”

Remote expert support through Valmet Performance Center

In addition to maintenance services conducted on site, Valmet offers remote support through Valmet Performance Center (VPC). VPC is a digital service hub offering customers a single point of contact whenever they need help, including a 24/7 support service line and optimization support to enable continuous improvement. VPC can provide remote support also to Valmet’s experts working on site.

“Our VPC experts can support mills with winder maintenance, optimization and troubleshooting, as well as startups and shutdowns,” says Mika Kari, Technology Manager, Digital Services Development, Valmet. “The dedicated winder specialists concentrate only on winder processes and automation, and they are backed up by a wide network of experts. This unique network gives us access to a vast amount of valuable knowhow and experience ensuring that even rare or complex issues can be solved quickly, hence minimizing downtime and improving predictability.”

Using Valmet Winder Diagnostics tool, experts at Valmet Performance Center can monitor winder performance in real time, letting them identify any operational issues.  

Service agreements for long-term support

Valmet offers tailor-made service agreements for all parts of the paper and board machine, including winders. The agreement and its targets are always negotiated together with the customer.

“Our service teams support customers with a full range of skills and competencies – from basic mechanical engineering to advanced automation and process expertise – covering the entire production line from headbox to winder,” says Tatu Pitkänen. “With a tailored service agreement, customers gain long-term support that combines a variety of expertise, ensuring stable performance and continuous improvement over the winder’s lifecycle.”

Training ensures that expertise is passed on

One of the current challenges in the paper industry is the retirement of experienced mill staff and the onboarding of younger personnel. Valmet supports its customers through this transition by providing training for operators.

“Winders are complex pieces of equipment, so operators need a solid understanding of mechanics, processes, and automation. Our training can be tailored to meet the customer’s particular needs related to operator competencies – whether its young professionals acquiring new skills or more experienced operators updating their knowledge. And of course, safety is always an essential part of the training,” says Katriina Geijer, Senior Manager, Customer Training, Valmet.

The lifecycle approach restores winder performance

As winders age, their mechanical and control systems must evolve to meet new production demands, quality expectations, and safety requirements. Valmet’s rebuilds and modernization solutions extend the operational life of existing winders, restoring their performance to current standards.

When winder replacement becomes technically and economically the best option, Valmet OptiWin portfolio offers modern, configurable solutions tailored to mill-specific needs. The product range covers a wide span of machine widths and production capacities, with configurable designs tailored to specific process and integration requirements.

Installation of a new winder marks the start of a new lifecycle, and by continuing to utilize Valmet’s winder services, mills can rely on sustained performance and process reliability for decades to come.

Text: Peter Cura & Marianne Valta