A Study of Advanced Finishing Control Implementation on a Supercalender, PaperCon2017
Operation of a supercalender requires the operator to control a number of sometimes conflicting qualities and objectives, using a number of manipulated variables. The complexity of the control on this process is such that, even when the supercalender is equipped with scanning gloss and caliper measurement, a human operator has difficulty in achieving all quality and productivity objectives. Typical supercalender objectives include achieving machine-direction (MD) gloss and caliper targets, minimizing cross-direction (CD) gloss and caliper spreads, minimizing gloss twosidedness, maximizing throughput, and minimizing manufacturing cost.
This paper discusses the incremental results that multivariable control and optimization can provide in control of a supercalender. The implementation of additional energy sources, coupled with process knowledge, innovation, and the availability of appropriate tools in the machine-direction and cross-direction controls, facilitate realization of optimal results.
The objective of the effort described in this paper was to deploy model-predictive multivariable machine-direction control, in conjunction with model-predictive multivariable cross-direction control, on a supercalender equipped with induction profiling actuators. Control objectives included minimizing machine-direction and cross-direction variability in gloss and caliper, minimizing gloss twosidedness, maximizing caliper, while increasing throughput and reducing product cost through coating formulation changes, and maximizing use of lower cost energy sources.
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