Tissue360 - Fall/Winter 2016 - 15

Joe Pankratz, VP of manufacturing, is responsible for the Natchez
operations and those at the Cordova, N.C., tissue mill. His paper
industry career started in 1980 with Fort Howard in Green Bay, Wis.,
in the lab technical department and process engineering on paper
machines. He subsequently went from Fort Howard to Pope & Talbot in
the western part of Wisconsin, where he served as technical director
and then superintendent. After Pope & Talbot bought a paper mill in
Ransom, Pa., he transferred there as superintendent. After several
years at the Pennsylvania mill, Pankratz went to work for three years
with a Hong Kong firm in China and was involved in the construction
of a couple of tissue mills there. His plan was to work there three or
four years, then return to the states and work to supply those operations with wastepaper from the U.S. in the fiber end of it, sending
fiber back and forth. He ended up going back to the states in 1999,
to his old mill in Green Bay, which was then Fort James, working the deinked plant there, and
eventually managing all of their nonwovens operations. He accepted an opportunity to come
with von Drehle in 2007, at the Cordova, N.C., mill, as plant manager, and was later promoted
to VP of manufacturing, a title he now holds for the Natchez mill as well.

Gary James,
production manager, is responsible for deinking
and papermaking at Natchez.
His career in the
paper business
began in 1996 at
Laurel Hill Tissue
in Cordova, N.C.,
a mill that von
Drehle acquired
in 2007. He
stayed at Cordova until 2006, when he
went to Nalco Chemicals, spending 10
years there. He started with von Drehle
on June 5, 2015.

"We had basically used up all of our capacity at Cordova and were looking to expand. For about
six months, we canvassed the country looking for the best sites. I told von Drehle that we are
going to find a facility where we can use a good piece of what's already there. The Natchez site
had 100 acres, lots of stainless steel tanks, pipes, and various pieces of equipment we could
use. It was a perfect fit for us," Pankratz says.

The Cordova mill operates two DCT
100 tissue machines-one a dry crepe
machine and the other a wet crepe
machine. It has a production capacity
of 58,000 tpy of tissue and towel paper.

of that is captive to the mill's own converting
operations, with the remaining third shipped
out as jumbo rolls, mainly to von Drehle's
Memphis, Tenn. operations. Some is sent to
the company's Las Vegas, Nev., converting plant,
and a little goes to its plant in Maiden, N.C. (see
sidebar on this page). The Natchez operation
currently employs some 125 people, a number
that is expected to ratchet up to near 150 as
the mill brings its fifth converting line up and
moves toward sustained, maximum output during the coming months.
Tissue360o magazine recently visited the
von Drehle mill in Natchez to gather more
information on its operations, meeting with
Joe Pankratz, VP of manufacturing, and Gary
James. Pankratz has the same title and responsibilities for both the Natchez mill and the company's Cordova, N.C., operations. Details they
provided of the Natchez mill are summarized
in the following sections of this report.
Pankratz explains that "When we set out looking for a new machine, our first goal was based
on the premise that there has to be a better, more
efficient way of making tissue than our current
technology that uses a suction pressure roll to
dewater and stick the sheet to a yankee dryer.
To be efficient, you have to dry the sheet in the
most cost-effective way. That led us to a shoe
press, away from the dryer. There have been
shoe presses running up against yankee dryers on tissue machines in Asia for a number of

von Drehle Corporation
Established in 1974, von Drehle maintains manufacturing operations in North Carolina, Nevada,
Tennessee, and Mississippi. Its tissue mills in Cordova, N.C., and Natchez, Miss., produce
jumbo parent rolls from 100 percent recycled fiber for on-site conversion of away-from-home
tissue, towel, and dispenser products, and also ship jumbo rolls to the company's converting
plants in Memphis, Tenn., Maiden, N.C., and Las Vegas, Nev.
Through an international network of more than 400 distributor partners, the Hickory, N.C.based company sells towel, tissue, and dispenser products to industrial, commercial, and
institutional distributors, contract cleaners, and building maintenance service providers in
North America.
Von Drehle also supplies dispensers for its various tissue and towel products These units
have unique, innovative features, a stylish and attractive design, and are translucent for
easy monitoring. They also feature an impact resistant hinge system, a unique snap-out key
design, and a textured finish to hide scratches and smudges.

years now. We also wanted the ability to make
a different looking product and the ability to get
more out of our recycled fiber, so we considered
ATMOS technology along with TAD. Efficiency
(energy and fiber use) and recycled fiber performance were critical because our bread and butter is lightweight, lower-cost bathroom tissue.
"When we saw the Valmet configuration,
with the Sym-Press (a shoe press pushing
against a counter roll instead of the yankee),
we thought that had to be the way to go. With
this configuration, you're going to get the nip
right all of the time, regardless of operating
speed and paper grade. In the past, it took a
number of roll grinds and profile changes to
get something close, but not perfect for the
numerous grades that we need to run. These

were some of the up-front drivers to go with
the NTT technology," Pankratz emphasizes.
With the market that von Drehle is in, process efficiency is always a big issue, Pankratz
continues. "The entities that purchase our paper
don't really use it. They sell it to somebody else
for their restrooms. Price is always important,
so we have to keep our costs down. Textured
capability gives us performance and cost opportunities. NTT would provide the lowest production costs when running the smooth belt,
and opportunity for performance/appearance
running in the textured mode."
Von Drehle negotiated a good deal of trial
time on the Valmet pilot machine at Karlstad,
Sweden. "We were in Karlstad on three separate
occasions," Pankratz says. "At the time, Gary
Tissue360ยบ FALL/ WINTER 2016



Table of Contents for the Digital Edition of Tissue360 - Fall/Winter 2016

Tissue Industry News
PrimeService for Modern Tissue Machines
Making the Most of Opportunity in Tissue?
Reducing MRO Inventory Using RCM Principles
Vacuum Blower Saves 40-50 Percent Tissue Dewatering Costs
Tissue360 - Fall/Winter 2016 - cover1
Tissue360 - Fall/Winter 2016 - cover2
Tissue360 - Fall/Winter 2016 - 3
Tissue360 - Fall/Winter 2016 - 4
Tissue360 - Fall/Winter 2016 - 5
Tissue360 - Fall/Winter 2016 - Setpoint
Tissue360 - Fall/Winter 2016 - 7
Tissue360 - Fall/Winter 2016 - 8
Tissue360 - Fall/Winter 2016 - Tissue Industry News
Tissue360 - Fall/Winter 2016 - 10
Tissue360 - Fall/Winter 2016 - 11
Tissue360 - Fall/Winter 2016 - 12
Tissue360 - Fall/Winter 2016 - 13
Tissue360 - Fall/Winter 2016 - 14
Tissue360 - Fall/Winter 2016 - 15
Tissue360 - Fall/Winter 2016 - 16
Tissue360 - Fall/Winter 2016 - 17
Tissue360 - Fall/Winter 2016 - 18
Tissue360 - Fall/Winter 2016 - 19
Tissue360 - Fall/Winter 2016 - 20
Tissue360 - Fall/Winter 2016 - 21
Tissue360 - Fall/Winter 2016 - 22
Tissue360 - Fall/Winter 2016 - 23
Tissue360 - Fall/Winter 2016 - PrimeService for Modern Tissue Machines
Tissue360 - Fall/Winter 2016 - 25
Tissue360 - Fall/Winter 2016 - 26
Tissue360 - Fall/Winter 2016 - 27
Tissue360 - Fall/Winter 2016 - 28
Tissue360 - Fall/Winter 2016 - Making the Most of Opportunity in Tissue?
Tissue360 - Fall/Winter 2016 - 30
Tissue360 - Fall/Winter 2016 - 31
Tissue360 - Fall/Winter 2016 - 32
Tissue360 - Fall/Winter 2016 - 33
Tissue360 - Fall/Winter 2016 - 34
Tissue360 - Fall/Winter 2016 - Reducing MRO Inventory Using RCM Principles
Tissue360 - Fall/Winter 2016 - 36
Tissue360 - Fall/Winter 2016 - 37
Tissue360 - Fall/Winter 2016 - 38
Tissue360 - Fall/Winter 2016 - 39
Tissue360 - Fall/Winter 2016 - 40
Tissue360 - Fall/Winter 2016 - Vacuum Blower Saves 40-50 Percent Tissue Dewatering Costs
Tissue360 - Fall/Winter 2016 - 42
Tissue360 - Fall/Winter 2016 - cover3
Tissue360 - Fall/Winter 2016 - cover4