From dust reduction to automatic format management, and even self-sharpening blades: the solutions developed by Voith show how technological innovation and safety can improve operators’ working conditions in paper mills, while simultaneously increasing production efficiency.
In modern paper mills, one of the most delicate points for operator safety and production continuity is the final section of the line, where the paper web is cut, trimmed, and wound. This is where several critical issues converge: frequent grade changes, manual operations on sharp components, dust accumulation, and maintenance interventions that can generate unplanned machine downtime.
These factors affect both personnel safety and production efficiency. For this reason, many companies in the sector are investing in technological solutions capable of reducing the most hazardous manual activities and improving working environment conditions. In this context, the innovation introduced by Voith aims to transform the winding section—the so-called winder—into a safer, cleaner, and more efficient area.
According to Fabian Köberle, global product and service manager at Voith Paper, the challenge lies precisely in overcoming the traditional bottlenecks of the final production stage. The goal is to reduce risks for operators, lighten the workload, and at the same time increase the competitiveness of paper mills through greater operational efficiency.
Reducing dust to improve safety
One of the most common problems in cutting and winding areas is dust formation. During the trimming process of the sheet, tiny fiber particles disperse into the environment. Over time, these dusts can accumulate on machinery, increasing the need for cleaning and maintenance. Not only that: their presence in the air also represents a potential health risk for operators.
To address this problem, Voith developed a system called Slitter Dust Removal, designed to intercept dust directly at the point where it is generated. The system uses specially designed aerodynamically optimized suction devices that capture particles both from the upper and lower sides of the paper sheet during the cutting phase.
Before installing the system, a specific dust audit is carried out by measurement and diagnostics teams to precisely identify the areas where the highest particle dispersion occurs. This approach makes it possible to design customized solutions for each plant.
The results are concrete. In some cases, the system is able to collect up to half a ton of dust per year. This means a significant reduction in air pollution in the working area and, at the same time, a decrease in cleaning and maintenance activities.
The experience of the Schoellershammer paper mill in Düren, Germany, is illustrative. Here, the system was installed on the PM6 paper machine. According to Christoph Nahrath, production manager of lines PM5 and PM6, the solution represents an important step toward the goal of a virtually dust-free winder. The particles generated during cutting are extracted directly at the source and no longer disperse into the environment. The result is a reduction in cleaning operations and greater protection for operating personnel.
Automation and new technologies to eliminate risks
Beyond dust management, another source of risk in the final production section is manual operations related to grade changes. Traditionally, these activities require direct operator intervention, who must adjust cutting devices to adapt them to the width of the paper web. These operations can take time and involve exposure to potentially dangerous mechanical components.
To reduce these risks, Voith developed the FastFormat solution, a fully automatic system that precisely adjusts trimming knives according to the required width. Automation makes it possible to perform format changes without manual intervention, reducing operator workload and minimizing the possibility of errors.
The automation logic and high positioning speed also significantly reduce format change times. In some installations, daily production time can increase by up to about one hour simply thanks to the reduction of manual operations.
An example comes from the DS Smith plant in Witzenhausen, where recycled packaging paper is produced. Here, the solution has brought benefits in terms of both productivity and safety. According to Ulf Heiligtag, Head of Technology at the company, the system represents an important step toward an increasingly automated production process.
Safer blades and continuous support in the mill
Another critical element in the cutting section concerns blade management. The knives used for trimming must be replaced periodically, an operation that exposes operators to the risk of injury.
To improve safety, Voith introduced the SharkBlade self-sharpening blade, designed to maintain its cutting performance for a longer time. Its lifespan can be up to four times longer than conventional blades. This means fewer replacements and fewer manual interventions.
When replacement becomes necessary, a quick-change system allows the operation to be completed in less than one minute, more than five times faster than traditional industry standards. In addition, the blades are transported in dedicated containers that ensure safe handling.
Alongside technological innovations, Voith has also developed closer collaboration models with customers. One example is the Mill Resident program, which involves Voith engineers being present directly at paper production sites. These specialists work closely with maintenance and production teams to accelerate problem resolution, improve spare parts management, and prevent unplanned downtime.
The result is faster communication and greater operational continuity. The stated goal is to completely eliminate unplanned machine stops.
Toward safer and more attractive paper mills
The technological evolution of paper mills is not only about increasing productivity. Increasingly, innovation is also focused on safety and the quality of the working environment.
Reducing dust, eliminating the most dangerous manual operations, and improving the ergonomics of daily tasks means protecting operators and at the same time making the sector more attractive to new generations of technicians.
In this scenario, the solutions developed by Voith demonstrate how the combination of automation, engineering design, and customer collaboration can contribute to creating safer, more efficient, and more sustainable paper mills. A goal that today represents a strategic priority for the entire paper industry.