Online variability analysis of paper and board for process optimization

Aim and goal

The goal of the project is to develop, evaluate and implement a methodology that allows for the analysis of variations of basis weight and moisture of the entire produced area.

Challenge

In the production of paper and board, reducing process and quality variation is as important as increasing the quality of the product. Keeping variation low prevents unwanted production breaks and thus raises production efficiency. Here, an extensive analysis of the produced product is critical. Unfortunately, using today’s measurement techniques, not more than 1 percent of the total produced area can be analysed.

Solution

The methodology is based on visual and infrared imaging. The images will be converted into product property maps, which are then used to analyse the property variation. This allows for the identification of the origin of the variation. The methods will be tested and optimized in case studies in the paper and board mills of the 6 mill partners.

Effect

The results of the case studies will lead to recommendations for the mills on how their processes can be modified to reduce the variation. This will help the mills to improve both product quality and process efficiency. A significant reduction in energy and raw material consumption will be the consequence. The methodology will also open to developing new services, for example high resolution “quality labelling” of the product, which will make printing, converting and packaging processes easier.