Pulp & Paper Industry Home
Video Case Study
Major improvements to process performance were acheived with
PlantTriage®. Watch this video to see how Kruger paper
reduced new machine start-up curve by months. Whether you are
an existing mill, or starting up new equipment, you can learn
from Kruger's experience.
Windows Media video, 12 mins
View the Video Now
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As Pulp and Paper Mills continue to "do more with
less", your resources are stretched thinner than ever.
You need to find ways to make sure that every part of your
plant is performing at its best, 24 hours a day. And you
don't have a lot of time to do this. The competition is
always tough, and you need to find every possible edge to
optimize your business profits.
PlantTriage®
Performance Supervision system looks after your thousands of control
measurements, 24 hours a day. It ties in to your existing control
system to scan the entire process, find the important
information, filter it based on your needs, and notify you
directly.
How ExperTune and PlantTriage Can Help
Extensive Experience in Pulp & Paper
ExperTune has been improving control loops in the Pulp &
Paper industry for nearly 2 decades. ExperTune is widely
recognized as the leader in control loop optimization. We
understand the specific needs of Pulp & Paper, and our
products have been designed to meet some of these very
specific needs.
Some examples of our experience are included in
Case Studies
Variability Reduction
Reducing variability is a sure–fire way to improve the
process. When you tighten up control on key variables, you
can close the "Opportunity Gap" by moving setpoints
closer to their spec limits. This is one of the simplest and
most effective ways to generate savings in a paper mill.
Imagine the money you could save by making even a small
adjustment to Basis Weight.
Energy Reduction
Most paper plants that implement PlantTriage® software
save from 0.5% to 5% on energy costs. Reductions come from tighter
control of energy–consuming processes, especially papermachines.
Learn techniques to save energy costs:
Watch this Presentation.
Manage Maintenance Costs
One study has reported that 50% of plant maintenance is not
necessary, and 10% is actually harmful. How do you know that
you are working on the right things?
Using the tools included in
PlantTriage® and
PID Loop Optimizer, you can
identify equipment issues, and even measure the extent of the
problem. This information can be used to plan maintenance
activities. In one plant, this approach resulted in a 60%
reduction in planned control valve replacements, saving days
of labor, and tens of thousands of dollars.
Cost Savings
When you know where to look, there are plenty of opportunities
to save money, increase production rate, and reduce downtime.
PlantTriage® shows you where to look. For example, the
Biggest Payback Loops shows
you the top 10 candidates for improving performance in the
plant.
Faster Problem–Solving
PlantTriage's Dashboard displays concentrated information so that you can
see at a glance exactly what information you want. Because the
information is provided in a web browser interface, you can get all
this information from your desktop computer. For example, the
TreeMap, shown here, is a new, powerful visualization tool
that helps focus your attention on the "Hotspots".
In addition, powerful drill-down tools help you make sense out
of the data faster than ever before. Imagine being able to
identify the biggest improvement opportunity in the plant, and
then drill down directly to the root cause. This is the kind
of power you get with the
PlantTriage® Dashboard.
Reduce Process Interactions
A Paper Mill is a highly interacting process. Upsets in one
part of the plant have an effect in many other areas. It is
often difficult to find the source of intermittent problems in
the process, especially when you can only see a small piece of
it.
PlantTriage® includes powerful visualization tools to
help you see exactly where the interactions are coming from. Once you
know the source, you can start using the tools within PID Loop
Optimizer to eliminate the problem at its source. For more
information on these tools, click
here.
Gaining Alignment
No matter what your role, you don't run the plant by
yourself. Many other people are involved in making decisions
that affect production, maintenance, finances, and quality.
PlantTriage and PID Tuner provide out-of-the-box reporting
tools that help you to make your case. You can even e-mail
these reports directly to you, export data to Excel
for further analysis or to include in a presentation. This helps
everyone to see the problem as clearly as you see it, and makes
gaining alignment
faster than ever.
Control Loop Optimization
PlantTriage includes a copy of ExperTune PID Tuner/Analyzer,
repeatedly recognized by users as the #1 controller tuning software
package. This includes tools for PID Tuning, Linearization, and
Optimization.
Learn more about control loop optimization.
Develop Your Expertise
The way to improve your career is develop yourself. ExperTune's
training programs provide a mix of theory and practice to help you
to solve problems quickly. Join one of our training sessions or
schedule one for your site. Click here for
more on training.
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