From Stock Prep to Finished Product From Stock Prep to Finished Product

An integrated approach to develop cost-effective

solutions in Tissue
Jeff Peters
Tissue Applications Manager
solutions in Tissue
Tissue Applications Manager
Tissue Panel Acapulco
October 27-29, 2010
Shift Target = $$$
Program Overview:
The Process, Case Study, Summary The Process, Case Study, Summary
The Process
Six Key Elements
Process Measurement: Back to the Basics
Plan Development
Generating the Data
Wh t t d ith th D t What to do with the Data
Program Implementation
Results Analysis Results Analysis
Process improvement rule #1: If you dont measure it, how can
you improve it? back to the basics!
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you improve it? back to the basics!
Tissue Process ssue ocess
Inputs: Outputs:
Furnish
Fiber
Ash
Fi
Speed
Fines
Freeness
Brightness
Retention
p
Crepe ratio
Efficiency
Tissue machine
Converting
Crepe
Ionic demand
Zeta Potential
Chemical dosages
Formation
Converting
Handfeel
Softness
Andritz AG 2007
Crepe
Performance
Formation
Felt Performance
The quality/efficiency chain runs through the process with creping at the center
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The quality/efficiency chain runs through the process with creping at the center
Process Overview ocess O e e
Control
Quality
Water
Runnability
Fiber
Wet-End
y
(Sheet Breaks)
Operation Improvement
Goal:
Wet-End
Additives
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Reduce Total Cost of Ownership
Goal:
Variability Reduction a ab ty educt o
Increased Production
Optimize Chemical Costs
Stabilize process
Quicker Recovery from upsets Quicker Recovery from upsets
Improved Pulp Quality
Operating Flexibility
Shift Target = $$$
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Opportunities for Control Oppo tu t es o Co t o
Use Measurements from the field: Use Measurements from the field:
Consistency &Ash Consistency & Ash
Brightness & Fluorescence
Fiber Characteristics
Ch i l R id l Chemical Residual
Freeness & Retention
Charge & Zeta Potential
Quality Data
To build Control Solutions BTG focuses on: To build Control Solutions BTG focuses on: To build Control Solutions, BTG focuses on: To build Control Solutions, BTG focuses on:
Overall process solutions (wet-end through converting)
Each project has a sustainable payback
Projects merged into a Total Control Strategy
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Projects merged into a Total Control Strategy
Data Gathering ata Gat e g
Case Study WS/non-WS grades
O f Opportunities for Improvement
Brightness & ERIC
P l St V i bilit Pulp Stream Variability
Chemical Additive Control
Grade Change Grade Change
Sheet Defects
Creping Performance p g
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Survey Data Analysis
System Charge Syste C a ge
Wet Strength Grades Wet Strength Grades Non Wet Strength Non Wet Strength
-0.200
0.000
0.200
0.400
g g g g
System Cationic
Machine Runnability Problems
1 000
-0.800
-0.600
-0.400
C
h
a
r
g
e

(
m
l
)
-1.600
-1.400
-1.200
-1.000
-1.800
Date/Time
Machine Chest Headbox Whitewater
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Survey Data Analysis - Consistency Su ey ata a ys s Co s ste cy
Range Chart for Machine Chest
Blade Transmitter
0 700
0.500
0.600
0.700
Variation within blade transmitter capability,
but too variable for on-line freeness control
0.300
0.400
f
e
r
e
n
c
e

=

L
a
b

-

T
x
0.100
0.200
D
i
f
f
0.000
0
6
/
1
7
/
0
9
0
6
/
1
7
/
0
9
0
6
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1
7
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0
9
0
6
/
1
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/
0
9
0
6
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1
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0
9
0
6
/
1
8
/
0
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0
6
/
1
8
/
0
9
0
6
/
1
8
/
0
9
0
6
/
1
8
/
0
9
7
/
8
/
2
0
0
9

1
1
:
0
0
7
/
8
/
2
0
0
9

1
4
:
2
0
7
/
9
/
2
0
0
9

1
2
:
3
0
7
/
9
/
2
0
0
9

1
4
:
3
0
7
/
1
0
/
2
0
0
9

1
0
:
0
0
7
/
1
6
/
2
0
0
9

1
0
:
0
0
7
/
1
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/
2
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0
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1
3
:
0
0
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/
1
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0
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1
4
:
3
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1
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9

9
:
3
0
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1
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1
1
:
1
5
7
/
1
7
/
2
0
0
9

1
4
:
3
0
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Range UCL RBAR LCL
Plan Implementation a p e e tat o
Install high precision consistency transmitter
Install on-line freeness measurement/control
Install on-line charge control Install on-line charge control
Evaluate high performance creping blades
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Results to Date esu ts to ate
Fiber Cost Savings: RET-2502 - Optical Consistency Transmitter
Reduced consistency variation vs. blade type transmitter
Reducedbasis weight variation resulting in lower average basis weight Reduced basis weight variation resulting in lower average basis weight
Estimated fiber cost savings - $210,000/yr
Fines/Ash Management: PCT-20 On-line Charge Control
Optimizingfines/ashretentionandwet strengthresinefficiency Optimizing fines/ash retention and wet strength resin efficiency
Improved fines/ash retention resulting in reduced fiber consumption
Closed-loop control to optimize cationic polymer dosage rate
Refiner Energy Reduction: DRT-5500 On-line Freeness Control
Identified and verified refiners were working the fiber
Expert analysis refiners undersized for process
Modify refining strategy and/or install additional refiner
Closed-loop refiner control to minimize energy consumption
Improved Sheet Quality: High Performance Creping Blades
Reduced bulk variation
Reduced lost time vs. steel blades blade life 60+ hrs vs. 12 hrs
I d i d bilit k d d
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Improved winder runnability no cracked edges
Summary Su a y
Understanding wet-end variability is the first step in process
improvement
R b Remember,
if you dont measure it, how can you improve it?
Improved wet-end stability
more uniform sheet to the Yankee
improved creping performance
reduced MD and CD variation
More uniform sheet to the rewinders and convertingg
more quality cases/day out the door
significant overall mill profitability improvement
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Latest Technology Developments atest ec o ogy e e op e ts
Global economy corrections
BTG continued to invest
The latest solutions technology The latest solutions technology
Fiber Cost Optimization
E C t R d ti Energy Cost Reduction
Chemical Cost Savings
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Complete Process Optimization
Fiber Cost Optimization be Cost Opt at o
RET-2501 and 2502
Optical technology for the most accurate measurement Optical technology for the most accurate measurement
RET-2502 measures total and ash consistency
Reduce consistency variation
RET-5503
Optical technology for non-pressured applications
Measures total and ash consistency
Install at white water chest for a fines/ash management program to
optimize tissue softness and absorbency
Benefits Benefits
Reduced process variation
Reduced basis weight variation
With the high cost of fiber a 0 1gsmreduction in BWvariation saves
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With the high cost of fiber, a 0.1gsm reduction in BW variation saves
$100,000+/year in fiber
Fiber Cost Optimization be Cost Opt at o
MEK-3000 TwinTorgue
TM
Designed for the most demanding applications Designed for the most demanding applications
Handling consistencies from 1 16%
Reduce consistency variation
Small and lightweight for easy handling and exceptional
installation flexibility
MBT-2500 Moving Blade Transmitter
f f % Active type unit for measuring consistencies from 1.5 8%
Excellent choice for less demanding applications
B fit Benefits
MEK-3000 is a very versatile unit capable of accurately
controlling consistency of various pulp types over a broad
range of consistencies
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g
MBT-2550 is the best overall value for your money
Fiber Cost Optimization be Cost Opt at o
BT-5400UV Brightness Meter BT-5400UV Brightness Meter
Measure five wavelengths
Blue, green, red
IR IR
NIR or optional UV
Measure values Measure values
Brightness
Color (L*, a*, b*)
ERIC (Effective Residual Ink
Benefits
Chemical dosage
optimization
Count)
Fluorescence (OBA)
Fiber brightness
optimization
Fiber blending
optimization
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optimization
Energy Cost Reduction e gy Cost educt o
DRT-5500 Freeness Meter
On line freeness measurement On-line freeness measurement
Closed-loop refiner control
Minimize refiner energy by:
Optimizing consistency control
Controlling fiber freeness level to optimize sheet
properties
Benefit
More uniform sheet properties
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Reduced energy consumption
Chemical Cost Savings C e ca Cost Sa gs
PCT-20/TSS-71
On-line charge
Benefits
Eliminate unexplained
g
measurement
Mutek PCD-04 technology
Up to 4 sample points
Eliminate unexplained
upsets
Fines/ash management
WSR Optimization
Thick and thin stock
WSR Optimization
Improved Yankee coating
control
I d h t lit Improved sheet quality
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Complete Process Optimization Co p ete ocess Opt at o
TTC (Total Tissue Capabilities Program)
Identify pain points and bottlenecks Identify pain points and bottlenecks
Develop control strategies to eliminate and/or minimize
upset conditions
Yankee creping optimization
High Performance Creping Blades
Benefits
Reduce process variation
Shift Target = $$$
Reduce process variation
Highest quality, most uniform sheet to converting
Optimize converting process
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Optimize converting process
Maximize number of cases per day out the door