Pulp and Paper

01. Optimizing PM Schedules: Data-Driven Approaches to Preventative Maintenance in Pulp & Paper

Moving away from fixed maintenance schedules is a critical operational shift for mills facing rising chemical, energy and water costs plus ever-tighter environmental rules. Plants now use real-time data to guide every maintenance action, unlocking higher machine availability, lower energy waste and on-spec sheet every reel. The goal is to perform the right task on the right asset at the right moment—guided by live information, not the calendar alone.

What is Preventative Maintenance (PM) and Why Optimize It in Pulp & Paper?
Preventative maintenance is a proactive strategy that schedules inspections, doctor-blade changes, bearing lubrication and roll grinding before breaks or quality losses occur. In a mill this covers everything from chipper knives and digester agitators to dryer cans and winder slitters. Optimizing PM is vital because an unplanned stop on a 1 500 m/min linerboard machine can erase 2 % of annual output in a single day.

Traditional PM follows rigid intervals—say, a dryer-can bearing grease job every 2 000 hours. This is better than “run-to-failure,” but it ignores real operating context: stock freeness swings, steam-pressure cycles, wet-end chloride spikes or seasonal temperature ramps that accelerate bearing race corrosion. Optimization shifts the trigger from time-based to condition-based, cutting unplanned downtime and avoiding the hidden costs of over-maintenance (grease waste, sheet staining, human error during re-assembly, lost dryer thermal profile after an unnecessary entry).

Traditional methods relying on fixed operating procedures and historical experience show clear deficiencies in addressing rapidly changing market demands and production complexities. These limitations result in low resource utilization, significant quality variations, and frequent unplanned downtime, creating an urgent need for smarter operational strategies.
02. The Limitations of Traditional Time-Based PM in Pulp & Paper

The core issues in traditional pulp and paper production lie in the latency of process control and the isolation between systems. Operational decisions are often based on periodic data rather than real-time insights, leading to two main challenges: first, "overconsumption," where resource usage exceeds actual needs; second, "efficiency losses," where capacity is underutilized due to process variability and unexpected stoppages.

Introducing Data-Driven PM: The Future of Mill Maintenance
Data-driven PM turns the traditional model on its head. Low-cost wireless sensors (vibration, temperature, motor current, oil debris, IR alignment) are mounted on critical assets—chipper motors, digester agitators, fan pump inverters, dryer cans, winder slitters.

IIoT gateways stream this data to on-prem or cloud analytics where AI/ML algorithms learn the “digital fingerprint” of each asset. When deviation is detected—say, a 25 % rise in dryer-can bearing temperature coupled with rising motor current—an automated work request is generated, scheduling the exact repair task hours or days before functional failure.

Key Data Points for Smarter PM Scheduling in a Pulp & Paper Mill
This advanced approach transforms pulp and paper production from segmented, predefined operations into dynamic, self-adapting processes. The system relies on several core technologies to achieve this: real-time control systems ensure continuous monitoring and adjustment of key parameters; specialized industry teams design and implement tailored solutions based on extensive application and process knowledge; end-to-end support covering from woodyard to processing and tran
03. Specific Applications in the Pulp and Paper Industry

We provide integrated solutions encompassing products, services, and global support to help pulp and paper mills achieve their operational objectives. These solutions include: Real-time control and maintenance of key process parameters, enabling companies to flexibly respond to diverse customer requirements while stabilizing product quality and enhancing production efficiency. Manufacturing automation and control systems, designed and deployed by our specialized teams leveraging deep industry knowledge and practical experience, helping enterprises optimize resource allocation and reduce water, energy, and material costs.

Data-Driven Approaches to Preventative Maintenance in Pulp & Paper
The Limitations of Traditional Time-Based PM in Pulp & Paper
Specific Applications in the Pulp and Paper Industry

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Pulp and Paper

01. Optimizing PM Schedules: Data-Driven Approaches to Preventative Maintenance in Pulp & Paper

02. The Limitations of Traditional Time-Based PM in Pulp & Paper

03. Specific Applications in the Pulp and Paper Industry

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