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Paper Machine Press Section Rebuild

A leading paper manufacturer planned a major rebuild of its paper machine press section to increase production speed, improve machine maintainability, and enhance dewatering efficiency without affecting ongoing plant operations.

The project involved complete design engineering of the modified press section while integrating new components with the existing running machine. The engineering scope covered structural design, detailed engineering, strength verification, manufacturing documentation, and installation support

ALTEN supported the rebuild and upgrade of a paper machine press section, aiming to enhance operational performance and maintainability. The project involved redesigning and replacing key structural components such as press frames, dryer frames, and walkways while upgrading machine speed from 600 m/min to 750 m/min.

The scope included:

  • Site measurement and analysis
  • 3D engineering and detailed design (frames, walkways, roll systems)
  • Manufacturing drawings and BOM creation
  • Roll and felt change system improvements
  • Integration with existing machinery and layouts

Challenge:

  1. Legacy System Integration
    • Adapting new designs to existing machine layouts and structures with incomplete or evolving input data
    • Ensuring compatibility with existing hydraulic systems, piping, and operational constraints
  2.  Space Constraints
    • Limited space for walkways, roll movement mechanisms, and maintenance access
    • Complex interfacing between frames, piping, and auxiliary systems
  3. Performance Upgrade Requirements
    • Increasing machine speed required structural redesign and revalidation
    • Ensuring strength and reliability of frames and roll change mechanisms under higher loads
  4. Maintenance Accessibility
    • Need to improve felt and roll change operations without extensive downtime
    • Designing mechanisms for safe and efficient maintenance activities
  5. Concurrent Engineering Complexity
    • Multiple teams (design, analysis, site, manufacturing) working simultaneously with evolving inputs

ALTEN Solutions

  1. Integrated 3D Engineering Approach
    • Developed skeleton-based 3D models for frames and structures in absence of complete references
    • Optimized designs with cladded Stainless steel sheet on Carbon steel hybrid structures to balance durability and cost
  2. Site-Driven Design Validation
    • Conducted detailed on-site measurements using laser tools and digital instruments
    • Continuously updated models based on real conditions and client feedback
  3. Enhanced Mechanical Design
    • Redesigned:
      • Press and dryer frames
      • Roll movement mechanisms for Press section
      • Roll change systems with cross beams, dollies, and rail assemblies
    • Incorporated hydraulic cylinder optimizations and loading arm improvements for reliability
  4. Maintainability-Focused Engineering
    • Introduced:
      • Improved felt change systems (spacer block arrangement)
      • Accessible roll extraction systems using crane-assisted operations
      • Thoughtful walkway layouts ensuring safe maintenance access
  5.  Structural Optimization & Analysis
    • Performed frame and roll change beam calculations ensuring load-bearing capability
    • Reduced machining allowance from 5mm to 3mm to optimize cost and manufacturing efficiency
  6.  Collaborative Execution Model
    • Enabled parallel workflows across:
      • Frame design
      • Walkway engineering
      • Structural analysis
    • Implemented iterative review cycles and milestone-based delivery

Business Benefits

Operational Efficiency

  • Increased machine speed by 25% (600 → 750 m/min)
  • Reduced downtime through efficient roll and felt change systems

Cost Optimization

  • Optimized material usage and machining allowances
  • Reduced manufacturing complexity through modular design

Improved Maintainability

  • Safer and quicker maintenance operations
  • Better accessibility through optimized walkways and layouts

Design Reliability

  • Robust structures validated through engineering analysis
  • Improved durability via optimized material selection

Faster Project Execution

  • Parallel engineering approach reduced overall turnaround time
  • Continuous stakeholder alignment minimized rework

Tools, Technologies & Expertise

Engineering & Design Tools

  • Advanced 3D CAD modeling tools (for frame and system design)
  • PDM systems for BOM and drawing management
  • Digital measurement tools (laser distance meters, vernier calipers)

Engineering Capabilities

  • Mechanical design & heavy equipment engineering
  • Structural and load analysis
  • Layout engineering and system integration
  • Manufacturing detailing (weld, machining, plate cutting drawings)

Domain Expertise

  • Pulp & paper machinery
  • Press section and roll handling systems
  • Industrial retrofit and rebuild projects
  • Maintenance optimization design

Where ALTEN Adds Value

  • Handling complex brownfield engineering projects
  • Delivering end-to-end solutions from site measurement to final drawings
  • Driving design optimization while maintaining operational continuity
  • Enabling simultaneous, cross-functional engineering execution

Why ALTEN

ALTEN combines on-site engineering insight, digital design expertise, and domain knowledge to deliver high-impact industrial transformation projects—on time and optimized for performance.