Reel & Roll Handling A deep look into the crane machinery at
Germany’s Palm paper factory Konecranes investigates the hoisting gears of the critical overhead cranes at the Palm paper factory, with Oil Analysis and Crane Reliability Study (CRS)
in Wörth am Rhein, Germany, annually produces some 650,000 tons of the versatile packaging raw material with surface weights of up to 160 g/m2. In order to safely transport these huge
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paper rolls day and night, the double-girder bridge cranes inside the factory must always function flawlessly. For this reason, Konecranes has closely analysed the gear oil of the cranes and used the endoscope to look deep inside the gears. Paper remains one of the most important
resources for the economy: According to the association of German paper factories, the paper industry sold approximately 23 million tons of paper, cardboard and paperboard in 2017 – up 1.4 per cent from 2016. The packaging industry is especially hungry for paper. Sales in this sector increased by 3.4 per cent last year alone. This is the area of operation for the paper machine 6 (PM6) at the Palm paper factory in Wörth am Rhein. The 650,000 tons of corrugated base paper it produces each year is handled at various stages by eleven double girder overhead cranes, all playing their own crucial role in the paper production on PM6. In order to safely transport these large paper rolls day and night, the hoisting gears of the eleven cranes inside the factory must always be in top operating condition. For this reason, Palm has asked Konecranes to look at eight of its most critical cranes. Following the results of the oil analysis and subsequent endoscopic
24 March 2019
hurning out corrugated base paper: The paper machine 6 (PM6) at the Palm paper factory
investigation, the maintenance experts identified a significant risk to future production and replaced one of the hoisting gears completely.
RECORD PAPER MACHINE PRODUCES AROUND THE CLOCK At the Palm paper factory, located in Aalen in Baden-Württemberg, everything circles around recovered paper. Nine paper machines in five factories annually produce approximately 2.2 million tons of newsprint
The cranes in the roll warehouse of the Palm paper factory are in use at all times. For this reason, one important element of the Konecranes CRS is inspecting the crane systems for signs of wear.
and corrugated base paper. The paper production continues around the clock. Correspondingly high are the demands
from the eleven double-girder bridge cranes that have been in use in the factory in Wörth am Rhein since the start of production in 2002. Collectively, they handle and store the completed paper rolls that weigh many tons. “The cranes are in use day and night,” says
Sven Bohrer, electrical engineer at the Palm paper factory. “If one should break one day, the production would have to stop, or at least greatly slow down, until the problem is solved. This would cost us time and money.” For this reason, Konecranes has closely
investigated the gear oil of the hoisting gears of eight of the eleven double-girder bridge cranes at Palm. Because you can look deep inside the oil, the wear metals and waste substances it contains make it possible to draw conclusions about the state of the entire gear. Nico Zamzow, vice president industrial
service EMEA central at Konecranes, comments on the method: “The oil analysis protects the crane. Any damage can be identified and treated early with its help. Moreover, system operators are able to optimise the maintenance and servicing of the cranes thanks to the detailed analysis report, and thus significantly increase their lifespan.” For the oil analysis at Palm, Konecranes
experts took samples from the hoisting gears of the eight double-girder bridge cranes. “The samples are analysed by our laboratory, which specialises in industrial drive train analysis. Here, the lab staff
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