Pulp to Paper Optimizer

The most common challenges faced by the board and paper mills

Lab samples, which cover only a small portion of the machine direction (MD) production over time, are used to verify the quality of the entire tambour. Due to delays in obtaining these results, operators often use expensive safety buffers to meet quality specifications, leading to increased costs and inefficiencies.

Human factors also play a significant role. Operators can only focus on a limited number of process variables at a time, and different operating philosophies from shift to shift can cause inconsistencies. New workforce members may have limited knowledge and learning capabilities, further complicating the situation.

Another major challenge is underutilizing the massive amounts of process, quality, and control data generated. This data, which could enhance efficiency and quality through advanced calculations and controls, is often merely stored without being fully leveraged.

Sustainability and resource optimization are critical concerns. High levels of automation and advanced control strategies can ensure consistent performance, leading to significant energy and raw material savings. Even small adjustments can accumulate substantial benefits over a year, highlighting the importance of continuous improvement and optimization.

Pulp to Paper Optimizer brings unique optimization results

Valmet Pulp to Paper Optimizer is an advanced process control (APC) that runs the board- and papermaking process automatically to the target production values with online predictions. It reduces end-quality variability as there is no need to wait for laboratory measurements before process adjustments. Valmet Pulp to Paper Optimizer leads to significant efficiencies as safety buffers of operator controller processes can be removed to the production of on-spec end-quality specifications.

The Valmet’s Pulp to Paper Optimizer utilizes Advanced Process Control (APC) technology to automatically optimize the process in terms of production, quality, and raw material costs. The solution also allows for the unique use of dedicated Valmet process analyzers, which offer excellence not available from any other similar system.

The primary target for process optimization is to facilitate savings through a more stable process operation. Advanced controls aim to reduce quality variability and stabilize the process, which would allow the process to be moved closer to the economic optimum compared with the baseline. The Valmet solution is designed to achieve mill quality objectives more accurately. The model will be updated regularly after implementation for long-term improvement.

Benefits

• More stable process
• Reduced end-quality variability
• On-spec quality
• Better machine efficiency with fast response process control
• Savings in raw material and energy
• Reduction of raw material consumption and thus costs