Executive Summary
Domtar Kingsport has always been a leader in delivering superior containerboard products. Our commitment to quality positioned us ahead of industry standards. By partnering with Maintech and implementing Dryer Section Passivation (DSP) technology, we have elevated our performance beyond expectations, setting a new benchmark for reliability, efficiency, and customer satisfaction.
Background
While Domtar Kingsport products were already outperforming market benchmarks, we identified opportunities to further optimize machine efficiency and reliability. Sheet breaks in the dryer section, caused by sticky deposits, impacted machine uptime and winder productivity.
Maintech’s Dryer Section Passivation (DSP) Technology
Maintech, a global leader in Dryer Section Passivation technology, provided a solution perfectly aligned with Domtar’s vision for continuous improvement. DSP technology prevents deposition on dryer cans, fabrics, and rolls, mitigating issues that compromise machine performance.
The increased production of recycled containerboard has resulted in higher consumption of recycled furnish. As machines continue to recycle OCC resulting in higher fines generation that cause runnability issues. This results in deposition of stickies on paper machine clothing resulting in sheet breaks, limited winder speed, and increased machine cleaning frequency. Consequently, more effective and complete solutions are required to address these problems.
Maintech USA is the N.A. division of Maintech Co., LTD, a Japanese company that invented Dryer Section Passivation 35 years ago. Maintech has over 1,000 passivation units running globally in Asia and Europe. Maintech expanded to N.A. in 2022 with Maintech USA headquarters in Atlanta, GA. Maintech Dryer Section Passivation (DSP) technology effectively prevents deposition on dryer cans, fabrics, fabric rolls, and calender rolls. The passivation application results in mitigation of stickieds deposition on paper machines thereby improving machine performance. DSP application is a complex technology consisting of chemical products, The condition of 1st dryer can Doctor blade on 1 st dryer can spray equipment, and application methods.
Maintech Partnership and DSP Technology
Key Features of DSP Technology:
- Prevents sticky deposits on dryer section components
- Reduce sheet breaks and manual cleaning
- Improves winder throughput and machine reliability
Benefits our customers experienced.
✓ Less frequent dryer section sheet breaks
✓ Increased machine speed [production]
✓ Reduced cleaning time and frequency
✓ Reduced operator’s manual cleaning and Improved safety
✓ Reduced steam consumption (energy costs)
Domtar Kingsport DSP Evaluation
Machine Details:
- Paper Grade: Recycled Liner and Corrugating Medium
- Production: 600,000 tons/year
- Machine Speed: 1,900 to 4,500 ft/min
Key Benefits Achieved:
- Eliminated manual cleanings on first dryer doctor blade
- Reduced deposition related to dryer can & felt related sheet breaks by 40%
- Improved winder throughput and operational efficiency
Maintech DSP Solution
DSP application point and passivation effect:
Two DSP applications were installed after a dryer section audit was conducted. These comparisons show that each treated surface drastically improved after using DSP. Accordingly, sheet breaks were reduced, and frequent cleaning of the doctor blades and dryer felts was no longer needed.
Customer Impact
Our customers now experience unparalleled reliability and performance. These improvements have strengthened trust and reinforced Domtar Kingsport’s reputation as the benchmark for excellence in the containerboard market.
Leadership Perspective
"Maintech has played a pivotal role in enhancing our operational efficiency. Their solutions have enabled us to streamline processes, reduce downtime, and achieve more consistent output—ultimately contributing to increased productivity & customer satisfaction." — Shivamurthy Modgi, Operations Manager
Conclusion
Domtar Kingsport’s collaboration with Maintech exemplifies our relentless pursuit of innovation and quality. By leveraging DSP technology, we have not only solved operational challenges but elevated our products beyond industry expectations, setting a new standard for excellence.
About the Author:
Takanori Tsuji is president and CEO of Maintech USA Corporation. With US offices in Atlanta and Chicago, Maintech provides chemical products, spray equipment, maintenance, and technical services. Contact
About Maintech
Maintech supplies a chemical and spray system as a solution for issues created in the dryer section caused by Stickies.
About Domtar Kingsport
Domtar’s Kingsport mill operates the second-largest containerboard machine in North America, with an annual production capacity of 600,000 short tons. It is also Tennessee’s largest OCC recycler, processing approximately 660,000 tons of recovered paper each year to produce recycled packaging for independent corrugated converters.
