Digital analysis in the press section: NipMaster increases efficiency and quality
With NipMaster, Voith provides an advanced analysis tool that supports papermakers in conducting data-driven optimizations on the shoe press section of paper machines. The simulation-based evaluations specifically enhance drainage, energy efficiency and overall production performance, contributing to improved sustainability, higher machine efficiency and consistent paper quality.
Efficiency, sustainability and production flexibility continue to be central success factors for the paper industry. Achieving these targets requires the precise design of the press section. In this area, Voith’s NipcoFlex shoe presses have delivered strong and reliable performance for decades, thanks to their robust construction and dependable operating characteristics.
A key technological advantage of Voith’s solution lies in the high press impulse generated by the interaction of an extended dwell time in the nip and an optimized pressure gradient. Both factors are essential to achieving maximum dewatering and maintaining stable paper quality. Optimal dewatering results from the coordinated interaction of a position-stable counter roll and a hydraulically loaded, concave pressure shoe, enclosed by a flexible press shell such as Voith’s NipcoFlex sleeve.
Holistic view of the press section
The shoe press, however, represents only one part of the press section as a whole. Experienced papermakers recognize that overall performance is determined by the complex interplay of all components. Only when felts, shoe press belts, roll covers and doctoring systems are precisely coordinated can efficiency, productivity and consistent paper quality be ensured.
NipMaster: Data-supported analysis for optimum results
For many years, papermakers have relied on Voith’s NipMaster software tool. It enables a data-based analysis of shoe press performance and combines this information with state-of-the-art simulation technology, backed by decades of process experience. NipMaster offers well-founded recommendations for optimizing both volume and dewatering concepts.
The tool accounts for each machine’s specific configuration and supports adjustments to various basis weights and other operating parameters. Results generated by NipMaster form the basis for optimizing dry content and overall dewatering efficiency in the press section. With these insights, all press section components can be aligned and refined accordingly.
NipMaster provides users with all relevant information required to address the challenges of the press section in a technologically sound and practical manner. “With the NipMaster approach, we not only offer technological excellence but also create measurable added value for production targets,” says Mario Neumann, Senior Application Manager at Voith. The optimization potential identified by NipMaster has a direct impact on production output and long-term operating costs.
Recognizing the tool’s value, Voith has continuously invested in the further development of NipMaster, ensuring even greater precision and broader analysis capabilities. The objective remains clear: to significantly enhance the efficiency and overall effectiveness of the entire press section.
Flexible analysis for a wide range of configurations
NipMaster evaluations are tailored to every press configuration, whether Single, DuoCentri, Tandem or Triple NipcoFlex. The software considers the broad spectrum of basis weights commonly produced on board and packaging machines.
“Ranges from 70 to 220 g/m² are not uncommon,” Neumann explains. As basis weights rise, initial dry content and machine speed typically shift as well, resulting in changing requirements for dewatering concepts. These must therefore be designed with both precision and flexibility in mind. NipMaster has repeatedly proven to be indispensable in supporting these adjustments.
The software can analyse numerous parameters, including current drainage performance, optimization of operating volume relative to specific pressure and water quantities, and the ideal coordination of belt surfaces and felts for different drainage types – such as tube suction or lateral nip drainage. This holistic approach is vital, as excessive operating volume can impair dewatering efficiency.
“Our goal is to precisely calculate and continuously optimize quality—from the surface of the shoe press belt to the counter roll,” Neumann notes.
Practical example: Tandem NipcoFlex – fine tuning matters
The Tandem NipcoFlex demonstrates how NipMaster can fine-tune a press section. For optimal performance, a precise distribution of drainage between the first and second nip is essential. Typically, the first nip handles around 75% of the dewatering, with the second nip completing the remaining 25%. Through NipMaster analyses, drainage profiles can be further refined by adjusting roll contact design, optimizing belt surfaces and avoiding over- or undercapacities.
“This level of fine-tuning is comparable to Formula 1- where the perfect coordination of even the smallest parameters determines success,” Neumann explains.
Conclusion
With NipMaster, Voith consolidates its extensive expertise in press section optimization. Any changes to roll covers, felts or belts are evaluated in the context of the entire press section system. This approach increases dry content, improves efficiency and runability, and ensures long-term optimization of existing installations. It is therefore no surprise that NipMaster has become the standard tool for shoe press analysis in the paper industry.
