In recent years, M-real and Metsä-Botnia pulp mills have used Cadmatic software extensively in their plant investments. The investments made so far in new production facilities in Joutseno have totalled more than 400 million euros. The new mills represent the most advanced technology and automation in the world. Cadmatic 3D systems were applied right from the start to the design of these investments, and the 3D models generated during the design phase will also be used in the future for the purposes of plant maintenance and process control. Modern 3D technology will also be used for designing the plant maintenance.

Engineering companies Jaakko Pöyry Oy and JP-Kakko Oy, both members of the Jaakko Pöyry Group, designed the new pulp line at the Joutseno Pulp mill of Oy Metsä-Botnia Ab. The assignment included turnkey design of the new woodroom, chip plant and pulp line facilities as well as modifications to the existing pulp drying machine.

The PULP2000 project started in autumn 1999, and the pulp line was commissioned on schedule in May 2001. More than ten designers at Jaakko Pöyry were involved in modelling the new pulp line.

The new pulp line meant a significant increase in the capacity of the whole mill, and a reduction in the environmental load, including odour. The new pulp mill produces 600,000 tonnes of bleached softwood pulp each year. Joutseno Pulp enjoys its reputation as a manufacturer of high-quality strong armouring pulp. The new mill represents state-of-the-art technology. The pulp line was practically re-built. The pulp drying machine was modernised, and its capacity increased to 2,200 tonnes per day, to comply with the output of the new pulp line.

Joutseno Pulp products are greatly valued by customers manufacturing magazine papers. The armouring grades produced by Joutseno Pulp are Pine 85, Pine ECF and Pine ARM. Their strength properties reflect the combined effect of the wood-based raw material and the pulp line machinery and process. Pine and spruce, timber and sawmill chips, are used as the raw material. The mill uses up to 3,5 million cubic metres of raw wood annually. The new pulp line completed the total renovation of the Joutseno Pulp mill. Now, the mill can fully utilise the capacity of the lye line, which was commissioned in autumn 1998.

People at Joutseno Pulp mill first became familiar with Cadmatic tools during the renovation of the lye line (the PULP 1998 project). Cadmatic 3D modelling was applied in the design of the soda recovery and turbine plants. In the PULP2000 project, the new woodroom and chip plant and the pulp line were designed by the staff at Jaakko Pöyry's Vantaa office, while the designers at JP Engineering's offices in Kouvola and Joutseno were in charge of the modifications to the pulp drying machine, as well as communication between the departments.

"Cadmatic 3D tools are optimal for piping design, which in fact constituted a major part of this project, too. The software proved particularly useful during installation. To assist the fitters in their work, we had two on-site workstations. Access to the 3D models made the installation work much easier and safer, and last-minute alterations caused no problems", Markku Karuvuori of Jaakko Pöyry explains. "For example, piping and cable trays were much easier and safer to install because of the 3D models. The 3D model allows the fitters to visualise the whole system. It is easier to locate the pipelines when you can view the whole system three-dimensionally onscreen", adds Juha Lempiäinen who works as the engineering manager at Metsä-Botnia and M-real mills in Joutseno.

Modifications to the pulp drying machine were designed in Kouvola. The designers first scanned the old inked-in drawings of the piping systems, and then modelled the new plant on top of the drawings using Cadmatic 3D software. "Modelling on top of the existing two-dimensional drawings was a really challenging job, and we had some problems. The auxiliary screen room was the only part we designed from scratch with Cadmatic", says Heikki Paavola, Chief Designer at JP Engineering. JP Engineering Ltd (JP-Suunnittelu Oy) is part of the Forest Industry business group of the Jaakko Pöyry Group, forming its domestic network. JP Engineering specialises in the implementation of investment projects for the paper, board, pulp and chemical industries.

M-real Corporation's new production facility in Joutseno was inaugurated in August 2001. The main consultant in the project, responsible for all engineering and design except construction engineering, was PI-Group. The Joutseno Pulp mill produces bleached chemithermo-mechanical pulp (BCTMP), which is used by paper mills as the raw material for high-quality printing papers, packaging carton and consumer packaging applications. The mill has a production capacity of 210,000 tonnes a year.

The mill manufactures mechanical pulp, using aspen as the principal raw material. A major user of the pulp is the Kangas paper mill, whose production orientation has changed over from uncoated to coated products. Galerie One is the best-known CTMP based printing paper. The BCTMP pulp mill in Joutseno is part of M-real Paper Group's investments programme, which has a budget of EUR 220 million, approximately half of which has been invested in the Joutseno production facility.

Since the mid-1990s, M-real's new construction projects have all been designed using Cadmatic 3D software. In other words, they have over six years' experience using Cadmatic tools. "In my mind, M-real has been the flagship in the papermaking industry as far as the use and development of Cadmatic software is concerned", says Kai Vikman, Technical Director at M-real.

"We also use Cadmatic software in document management and the design of modifications. Additionally, it is integrated with our machinery and equipment database for maintenance purposes. One could say that the software is one of the most essential components for the technical management of the plant throughout its lifetime", says Kai Vikman. He appreciates the user interface and its functionality: the virtual model is easy to read and understand. This is particularly useful for maintenance purposes.

"We are actively developing the software in co-operation with Cadmatic. As it is based on an open architecture, we have been able to adapt the software to meet our specific needs", Vikman says.

At M-real's request, Cadmatic software was used as the principal modelling tool by PI-Group, the main consulting company in this project. "For us it was the first time we used the software at our Vantaa office, but thanks to the excellent user support, we easily got used to the software", explains Rune Franzén, the project supervisor.

The project was undertaken by the PI-Group's Vantaa and Rauma offices and M-real's engineering teams at Joutseno. A total of 15 model designers were involved in the project, and from the very beginning, the modelling was based on the idea that future needs related to data management during the plant maintenance phase must be taken into consideration.