Pulp and Paper Automation and Production Services

Increasing Productivity for Pulping and Papermaking

control system engineering for paper and pulp industry

You need to respond to the challenges of the pulp and paper industry: tightening competition, mass customization with strict process parameters, higher operational and materials costs, and compliance with strict environmental and safety regulations. Economic realities suggest it is important for you to automate and optimize your pulp and paper processes and extend your current equipment’s lifespan, all while keeping improvement costs and shutdown time to a minimum. What is necessary to maximize safety and increase productivity while reducing energy and lifecycle costs? Seamless engineering solutions. Quad Plus can meet the demands of your pulp and paper production processes.

Why Choose Quad Plus?

Even though you need to maximize operating time, you also must implement changes to increase efficiency on your existing paper machine or winder. How do you do this? By working with a trusted partner that will precisely evaluate your current operational environment, design a consistent and efficient solution, and implement in a phased approach to lessen shutdown time.

Quad Plus has the paper production process knowledge to assess your current operations and design customized solutions to reach your specific paper mill targets. During the design phase, we utilize advanced process control to model behavior before implementation to mitigate shutdown time. The same engineers that design your solution then perform onsite installation and commissioning of the entire electrical system to ensure that newer technology and controls can be integrated and configured to work with existing equipment.

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Pulp and Paper Application Challenges

Reducing defects and bottlenecks while improving safety standards starts with identifying areas for improvement, and then having the right combination of expertise and technology to effectively solve the problem.

Web Handling Defects

analyze and engineer your pulp and paper production control system

The detection and elimination of issues such as web breaks, reeling wrinkles, slippage, and paper defects at their source can reduce the risk of slowdowns, emergency stops, and off-spec product rolls. Evaluating web tension and speed differentials, both in the winder and throughout the paper machine, can help diagnose and prevent flaws. Integrating real-time measurements can ensure moisture, web profile basis weight, and thickness are within the target range.

Production Bottlenecks

paper production control system cabinet

Bottlenecks can significantly limit your overall production capacity in both the paper machine and winder. Manual slitter adjustments, outdated process and control technology, equipment capacity limitations, vibration issues, and drive system inefficiencies need to be identified through machine data analysis and then addressed through automation, design, replacement of legacy equipment, and optimization or control processing and communication.

Safety and Standards

turnkey control system services for pulp and paper industry

Eliminating hazards, reducing liability issues, and meeting environmental standards is critical for the safety of your personnel and production capacity. Risk mitigation, meeting TAPPI and IEEE standards, automating slitter positioning and web threading functions, and adding safety features such as guarding, fencing, and implementing PLC-integrated safety features can dramatically reduce risks to your personnel and your products.

Pulp and Paper Process Design and Automation

machine and system upgrade for industrial paper production in a pulp mill
Implementing new control design methodologies and process automation opportunities can address many inefficiencies, specific issues, and outdated technology throughout the entire papermaking process. The results include extending the life of your equipment while adding the capability to increase speed, capacity, and productivity, reduce changeover times, and stabilize product quality.

Automating paper grade and parent reel changes, slitter adjustments, blade changes, and rebuilding sections of the control system that limit speed or capacity are projects with paybacks of additional product production. Automating more risky manual processes can also increase the overall safety for your personnel who can manage recipes, paper grade changes, and slitter adjustments from outside the paper machine and winder.

Pulp and Paper Line Optimization

You’ve already optimized a section of your line hoping to increase capacity, but then begin experiencing a bottleneck or slow down in another section. To resolve these unintended consequences, the entirety of the web handling process must be evaluated. The evaluation starts with an understanding of all current control systems and process capabilities, new technology potential, and the different characteristics of the product as it feeds through the machine. Then, using advanced process control modeling, solutions can be designed to accurately control speed differentials that accrue at different sections. The result is to collectively maximize the capacity of production without causing unforeseen issues further down the line.

For each section, the motor and coordinated drive systems need to be selected and designed based on the normal running load (NRL) and recommended drive capacity (RDC) calculations. The sectional motors load-sharing capabilities also contribute to achieving the power required to adjust to speed differentials in other sections. Design also accounts for the ability to respond to acceleration, deceleration, and braking and adaptive web tension control as the web is being formed, pressed, dried, calendered, and wound within the paper machine. The elimination of slowdowns and bottlenecks at the winder is critical to optimize performance. High speeds, dynamically adjusting motion control, precision tension, and efficient control communication are necessary to allow rapid changes to speed and torque while ensuring the product is unwound from parent rolls, slit, trimmed, and rewound without damage.
machine and system upgrade for industrial paper production in a pulp mill

Online Paper Profile Measurements

machine and system upgrade for industrial paper production in a pulp mill
Web gauging system integration allows for real-time, continuous measurement of paper thickness, basis weight, moisture, machine direction (MD) and cross-machine direction (CD) tension profiles at critical points. Monitoring and correcting profile and quality disturbances will improve wet end stability, reduce product variances and chemical usage, and reduce paper web breaks resulting in increased productivity and capacity.

As the quality measurements are scanned, data is stored in a database for further reporting and analysis after production. The reporting tools allow the identification and comparison of product qualities and narrow down the root cause of issues.

Operational and Performance Assessments for Pulp and Paper

Risk Assessment and Safety Validation

analyze and engineer your pulp and paper production control system

Pulp and paper operations are inherently dangerous due to the high speed and rotation of machinery, wet and slippery conditions, slitting and cutoff knives, and high temperatures. For new installations, before rebuilds, or after accidents, a safety review should be performed to identify and eliminate or protect people from hazards, or to automate protection systems. Lockdown of safety PLCs also prevents unauthorized programming changes, ensuring that the machine runs in a safe manner for personnel and products. Validation includes physically testing the machine state and ensuring that the expected outcomes are observed.

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Vibration Study and Analysis

paper production control system cabinet

Vibration should not cause paper defects, production interruptions, or add wear and tear to your machine. Whether done separately or part of the overall rebuild or optimization of the machine, vibration must be addressed. The study typically includes onsite sensor measurements, data collection, engineering analysis, and a report with recommended actions for both dynamic behavior and mechanical condition.

Power Studies

turnkey control system services for pulp and paper industry

Reducing energy consumption throughout the papermaking process allows your mill to meet government regulations, meet IEEE 519 standards, and decrease utility and operating costs. Electricity usage management ensures consistent energy availability at an optimum level for all equipment in the entire mill and improves secondary reactive energy control.

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Remote Support and Onsite Repair

Remote support is critical to minimizing downtime. It is vital that you have prompt, reliable remote support to identify and resolve your paper machine and winder issues. We can connect to your control systems to gather information, system alarms, and fault codes to make recommendations. If remote resolution isn’t possible, a technician will be dispatched to your mill, already prepared with the correct tools and parts, to provide onsite repairs.
machine and system upgrade for industrial paper production in a pulp mill

Pulp and Paper Case Studies

We have successfully completed projects for customers who produce containerboard, uncoated recycled paperboard (URB), fine paper, tissue, and towel. To learn more about the specific problems our customers were facing and the solutions we provided, please refer to the case studies linked below.

Services Available

Quad Plus offers a wide variety of services to assist you no matter where you are in the system integration lifecycle. For new builds, we offer design and project management services, for existing plants, we can make your operation run smoother and more efficient. For plants with obsolete control systems, we can assist with retrofits and upgrades. No matter your business need, we have you covered!

control system integration life cycle
control system integration life cycle

Pulp and Paper Industry Solutions

pulp and paper industry solutions company

Your internal engineers already have long to-do lists, and tasking them with upgrades on top of their regular workload would be a considerable demand. Instead, rely on the experts at Quad Plus to provide the analysis needed to understand your current operating environment. Then we can make smart recommendations and implement solutions designed to cut your operation costs, reduce waste, deliver shorter lead times, and improve safety and working conditions for your entire team.

Contact Quad Plus today.

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