Predicting paper breaks without you knowing it using BIG-AI, TAPPICon25

In the pulp and paper manufacturing industry, paper breaks are crucial problems that lead to production downtime, material destruction, and low operational throughput. To resolve these challenges, a novel approach Business Insight Generation using Artificial Intelligence (BIG-AI) is introduced to predict sheet breaks in real-time and improve productivity. BIG-AI uses customized AI algorithms to determine concealed indicators that conventional methods may not be able to detect. BIG-AI platform is equipped with analysing data drifts, model drifts, and CI/CD pipelines. BIG-AI extracts real-time data and produces operator-driven insights with root cause analysis and early warnings of sheet break indicators. The proposed BIG-AI solution has been piloted and rolled out successfully in some of the pulp and paper manufacturing divisions in South Africa, Indonesia, and India. BIG-AI predicted pulp and paper sheet breaks with an accuracy range above 60 % and in some cases reaching up to 85 to 90%. BIG-AI led to significant improvement in operations and reduced downtime by over a million dollars in savings substantial amount by each paper machine. BIG-AI also optimizes the processes and equips operators with insights on possible sheet breaks by highlighting variations in parameters like draw variation, HB cy variation, moisture variation, vacuum variation, etc. This empowers operators to investigate and proactively prevent sheet breaks quickly.BIG-AI showed the new transformation capabilities of the pulp & paper industry and addressed the long-standing process issues. The BIG-AI platform goes further to advance the cause by offering insights that are not only predictive but are insightful in the sense that they enable action.

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