As part of an initiative to boost the quality of folding box board grades produced at the Whakatane mill, Carter Holt Harvey Paperboard (CHHP) decided to explore upgrading the wet end of the No 3 board machine with a 3-ply Fourdrinier system and a modern machine drive configuration. Beca AMEC was commissioned to assist with a pre-feasibility study and later a full feasibility study. The brief entailed:
- defining the civil, structural, HVAC, mechanical and piping scope for the project
- preparing a cost estimate for these aspects as well as for the electrical and machine controls
- producing a specification for the new drive system
- completing the study within six weeks to meet the CHHP timetable for project submissions.
A major feature of the study was Beca AMEC’s structural support design for the new Fourdrinier. To support the increased loads new under-floor cantilever beams were proposed rather than additional piling.
Beca AMEC used the Plant Design Management Software (PDMS) package for 3D modelling during the study. Preparing a 3D model to show the proposed plant and piping changes allowed the conceptual design to be reviewed with CHHP and Fourdrinier equipment representatives.
The model not only proved less expensive to produce than the conventional approach, it also provided more effective communication of the design concepts to the project stakeholders.
This study subsequently developed into successful implementation of a new wet end for No 3 Machine. The structural design produced significant cost savings, reducing capital costs by NZ$1.25 million.