Tracking and Optimizing Reel To Winder Productivity in a SuperCalendered Paper Mill, 2006 Papermaker’s Conference

Results of automated tracking and optimizing of dry end productivity for a papermill producing supercalendered grades and having multiple papermachines, supercalenders, winders and mixed process lines is reported. The use of modular operator and data collection stations, together with RFID or Bar-Code automated reel tracking and a central database, allowed all paper slab and machine time losses to be automatically followed through the process path. The resulting accurate, automated and quick display of trends of left-on-spool and other slab losses provides the information operators need to use the reel sizing calculator tools most effectively. Floor inventory data and production run tracking aid in order fulfillment accuracy and reduce the costs of over and under runs. Reliable loss data provides focused information needed to minimize dry end slab and time losses. Some unique challenges related to the widely differing wound-in-caliper changes for supercalendered versus non-supercalendered grades were encountered, and overcome. The combination of reliable and precise visibility of losses together with unique operator tools for optimal sizing and consumption of reels resulted in 1.5 to 2% reductions in dry paper losses. Unaccounted slab losses, from before and after implementation, are shown along with current detailed monitoring results.