Klabin PM 28: Flexible board production with a state-of-the-art machine

In 2023, Klabin’s PM 28 board machine was successfully started up in Ortigueira Unit, Brazil, marking a major milestone in the second phase of the company’s ambitious Puma II Project. Designed for flexibility and scale, PM 28 is the largest board machine in Latin America, capable of producing a wide range of coated and uncoated board grades. Valmet’s advanced stock preparation and board machine technologies played an important role in supporting Klabin’s goals – enhancing energy efficiency, ensuring fiber quality, and delivering the process stability needed to meet evolving market demands. 

Klabin’s board machine PM 28 started up in Ortigueira Unit as part of the second phase of their large investment, Puma II Project. Klabin’s goal was to position itself as one of the leading coated virgin fiber boards and kraftliner producers in the world. 

The board machine is designed to be flexible, capable of meeting market demands and adapting to volatility. It can produce a large variety of board grades, from kraftliner to coated boards such as folding box boards (FBB) and liquid packaging boards (LPB). With an annual capacity of 460,000 tonnes, it’s the largest board machine in Latin America. Valmet delivered equipment for stock preparation and approach flow systems and board making line from headboxes to reel, followed by a winder with automated transfer rails and roll handling systems. 

The machine is state-of-the-art, featuring the best technology on the market and being the most competitive in the global board sector,” says Ricardo Cardoso, Industrial Director at Klabin. 

PM 28 is integrated with a new fiber line that includes a Continuous Cooking G3 system and a BCTMP line. The Valmet-supplied fiber line was also a part of the second phase of Puma II Project together with extensive automation and digital services.  

Efficient fiber treatment with comprehensive stock preparation 

As part of the Klabin Puma II Project, Valmet delivered a comprehensive stock preparation line and approach flow system for PM 28, tailored to meet high demands for energy efficiency, process performance, and product quality.  

Key components of the stock preparation line are the 13 Valmet Conical Refiner Pro units, which provide a highly efficient and fiber-friendly refining process. Klabin had already gained positive experience with this technology during their previous project with PM 27, where the refiners delivered excellent results in terms of fiber treatment and paper quality. Compared to traditional systems, these refiners enable more uniform fiber treatment and improved control over energy input, especially with their low no-load power consumption. This translates into better paper properties, including enhanced tensile strength, burst, and tear resistance, critical for kraft and board grades.

13 Valmet Conical Refiner Pro units provide a highly efficient and fiber-friendly refining process 

Another important element of the delivery is the Valmet Disc Filter, which plays a vital role in water and fiber management. Installed to treat white water from the machine, the disc filter enables the recovery of valuable fibers that would otherwise be lost to the effluent system. The cleaned water is then reused in the shower systems and other parts of the machine, reducing the need for fresh water intake. This contributes to lower raw material costs and improved environmental performance, making the disc filter an essential part of the mill’s circular approach to water and fiber use.

Valmet Disc Filter plays a vital role in water and fiber management. 

Superior quality and CD profiles with advanced technologies 

The PM 28 is equipped with three OptiFlo Fourdrinier headboxes and an OptiFormer Multi forming section with three fourdriniers that ensure uniform paper formation. The stand-out feature is the state-of-the-art middle ply OptiFlo Fourdrinier headbox. This headbox, equipped with an ejector-type dilution system, features CD profile control with a new 30-millimeter spacing. It effectively eliminates even the smallest error wavelengths of 6 centimeters or more. With this narrow spacing, Valmet now offers options of 30 mm, 60 mm, and 90 mm spacing, ensuring the best dilution control for each specific case. 

Klabin has been very pleased with the narrow dilution spacing. "You have fiber orientation adjustments, and now this new dilution control. We have seen superior quality and CD profiles in the middle ply, thanks to the advanced headbox technology and this new narrow dilution spacing," says Wagner Ouverney Santos, Production Paper Manager at Klabin.  

The OptiPress Linear with three shoe presses plays a crucial role in maintaining bulk and densifying the paper web. Other highlights include the OptiSizer Film sizer technology and two OptiCoat Jet coating stations, which ensure uniform coating application, essential for achieving the highest quality of board.

Advanced technologies in the wet end ensure superior quality. 

Training and optimizing with digital services 

The PM 28 start-up and optimization were supported by a comprehensive package of Valmet’s digital services . One absolute highlight is the Valmet Training Simulator, which enables personnel to safely practice hands-on procedures and scenarios and prepare them for troubleshooting. PM 27 and PM 28 in Ortigueira are the first board machines in the world with a fully simulated process.

“The knowledge acquired through the simulation trainings help the operators in day-to-day tasks. There is huge impact as the operator gains confidence and composure. With acquired knowhow and experience, they become adept and effective at handling diverse situations and anticipating machine behavior,” says Anderson Tomé, Industrial Manager at Klabin, and adds: “We also saw an important gain in adjusting the logics and parameters, which had a clear positive impact on the start-up curve.” 

Marcio Pegorari, Service Technician, Master at Valmet  

Another highlight has been the Advanced Process Controls (APC), which optimize the board and paper quality and raw material usage. Instead of controlling individual equipment, the APC is taking over multiple process areas and machine sections. Klabin’s experiences with the APC have been very positive.  

The third highlight is an automatic customer roll handling tracking system, which connects PM 28 to the new warehouse. This process is supported by an innovative radio frequency identification (RFID) tagging control system that enables traceability of the produced paper. In practice, the RFID tag is in the core and can be digitally read through the thick paper roll. Previously, operators had challenges visually locating the exact place of customer rolls in the warehouse. Today, forklifts equipped with RFID readers and smart software algorithms monitor all roll movements. The system can pinpoint the exact location of all rolls in the warehouse and manage the loading of all outbound orders, registering each shipped item and its destination. 

Collaboration at the core 

​The successful collaboration between Klabin and Valmet in the Puma II Project exemplifies the power of strategic partnership and shared innovation. By integrating advanced stock preparation systems, cutting-edge board machine technologies, and comprehensive automation solutions, the teams have delivered a highly flexible and sustainable production line. The PM 28, complemented by the new fiberline and BCTMP line, enables Klabin to produce a diverse range of high-quality board grades, including kraftliner, folding box board, and liquid packaging board, thereby enhancing their market adaptability and product portfolio. 

Reflecting on the project's development, Ricardo Cardoso concludes: “The development of the project was like a co-creation between Klabin and Valmet so that we could have the best possible execution of the project. Through our joint effort, we achieved excellent results and gained our customers' approval for our products. We are very happy with the results achieved so far.”