Consistency Control: Systematic and Scientific Design Leads to Many Different Strategies, 2006 Papermaker’s Conference

The objective of this paper is to show the importance of using the necessary tools to collect, evaluate and take the necessary actions to improve and optimize not just head box but overall paper machine performance to produce quality paper at low operating costs. It has been proven that one cannot rely on on-line dry end scanners alone, since the information obtained is too late in the process to make necessary changes. Since certain problems exist in the press section, such as moisture streaks, that on-line sensors cannot measure, a study was performed on the wet end of the paper machine using dedicated tools to detect these issues.

By adjusting certain head box parameters and addressing some of press section problems we were to achieve substantial cost savings. This study focuses on the impact as well as the results from the adjustments performed on the paper machine. The study was performed at a mill experiencing among other issues wrinkles, which resulted in both machine and winder run ability issues thus affecting production. Wrinkles, which typically originate from uneven moisture profiles in the press section, can actually worsen with increased machine speed. A higher than normal frequency of web breaks, which may be caused by severe wrinkles or by improper pressing, was also a major concern. This paper will point out recommendations for further improvements to machine efficiency and additional economic benefits that can be achieved by proper utilization of these tools.