Closed-Loop Vacuum Control in Papermaking: A Data-Driven Approach to Wet End Optimization, TAPPICon26

In the pursuit of smarter and more sustainable papermaking, the wet end of the paper machine remains one of the most critical yet traditionally under-automated areas. Vacuum levels in the forming section—key to early-stage water removal—are still commonly controlled manually or through static recipes, offering limited responsiveness to real-time process variations. This study introduces a novel closed-loop vacuum control strategy that leverages real-time consistency measurements to dynamically regulate vacuum application in the forming section.

By integrating advanced microwave-based sensors at key positions of the forming section and after the press section, the system continuously monitors sheet dryness and adjusts vacuum levels accordingly. The control logic uses a feedback mechanism to compare real-time, measured consistency values with target setpoints derived from the basis weight of the paper being produced. This enables the vacuum system to respond intelligently to changes in stock properties, machine speed, and forming fabric condition; factors that traditionally required manual intervention by experienced operators or conservative setpoints.

This approach represents a paradigm shift in wet end control, moving from static, experience-based settings to adaptive, data-driven automation. The results highlight the potential of closed-loop vacuum control to enhance energy efficiency, reduce process variability, and support more consistent and resilient machine operation. As such, this methodology offers a compelling framework for mills seeking to modernize their operations and embrace the principles of Industry 4.0.

The closed control loop allowed for a reduction in vacuum intensity of up to 30% in certain zones, leading to an overall reduction of electrical consumption of approximately 10-15% in the forming zone. These results were achieved without compromising product quality or machine runnability.

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