Pulp & Paper


  Industry Facts  
 

The PI System is found in over 450 mills around the world. Over 50 Pulp & Paper companies have made the PI System the standard information infrastructure in their mills. The PI System is the standard information system in 9 of the 10 largest Global Paper Companies and runs in the world’s largest mills.

        Learn how our customers are using the PI System

 


Mills need uninterrupted real-time data to solve problems in their business. Paper companies routinely use the PI System to manage and report on their sustainability goals, reduce energy and water consumption, provide visibility into process operations, and increase equipment availability – all resulting in increased profitability. Companies need PI System data for fast decision support to increase production yields, predict equipment failure, and to proactively plan and schedule maintenance.

Pulp & Paper companies worldwide use the OSIsoft PI System to provide the real-time data infrastructure and collaboration tools they need to meet key challenges, including:

  • Meeting Sustainability Goals
  • Integrating Mill-wide Information Into Business Systems
  • Maximizing Asset Performance

Sustainability in Pulp & Paper

“Sustainability” in Pulp & Paper means more than just good stewardship. Exercising best practices in forest management and increasing recycle content in products are typically the areas that gain the most media attention. Yet, when mills set operational sustainability goals, energy, water and waste reductions top the list of priorities. Customers with the PI System collect data from all sources and use our tools to:

  • Monitor real-time energy usage and water consumption throughout the process to gain insight on where improvement and process modifications can be made.
  • Automatically alert individuals when consumption in certain areas goes out of limit.
  • Build environmental alerting and reporting.
  • Bring real-time energy data from all sources in the mill into a single portal environment and quantified by ton of production to gain insight into true manufacturing costs.
  • Optimize energy generation and balance with consumption based on real-time ties to the mill’s electric provider. In some cases, mills use the PI System for energy sourcing decision support of “make-versus-buy” on their power grid.

  Smart Papers, Hamilton, OH  
 

Most of the hype around Smart Grid is about the residential meters. Smart Papers, the company that manufacturers and markets some of the best premium coated papers in the world, has leveraged aspects of Smart Grid and the PI System in order to manage energy usage on a real time basis and reduce costs. Improved operations and greater stability of the electric power grid at the Smart Papers node were added benefits. In this presentation, Dan Maheu, President and COO of Smart Papers, describes their strategy, implementation, risk mitigation and benefits. He also discusses obstacles and how they were successfully overcome.
  
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Integrating Mill-wide Information into Business Systems

Mills are finding that real-time information can help close the gap in their corporate business systems. Whether the information is raw material consumption, real-time production, quality information for certificates of analysis or alerting maintenance for equipment problems, the PI System can provide timely information and help automate manual processes.

One pulp company in Brazil started exchanging quality information with their business system to speed up shipments and automate the disposition of Certificates of Analysis. Once this project was implemented, the mill found numerous additional uses for mill-wide data exchange. And since the architecture was already in place, the incremental cost to implement was small while the project payback was large.

  Klabin, Sao Paulo, Brazil  
 

Klabin is the biggest producer, exporter and recycler of paper in Brazil. Market leader in packaging paper and board, corrugated boxes and industrial sacks, it also produces and sells timber in logs. In the following presentation, Klabin uses the PI System software to integrate its real-time information to its SAP business system for production planning, quality assurance and automated plant maintenance.
  
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Maximize asset performance through real-time monitoring.

The average age of paper mills in the world is 28 years. In North America, that average is 38 years. In addition to its aging assets, the Pulp & Paper manufacturing process is rife with large rotating equipment, harsh chemicals and high temperature/pressure operations. Effective maintenance of this equipment can help ensure a safe working environment. In addition, timely maintenance will increase overall equipment effectiveness. Other areas that benefit from good maintenance programs are:

  • Improve capacity planning and scheduling by ensuring that equipment can handle the production load.
  • Reduce the need and costs for extra spare parts and warehouse storage space with real-time updates on inventory requirements.
  • Install equipment sensors to collect real-time asset performance data, gain a clear picture of asset health, and receive real-time predictive warnings.
  • Reduce production downtime, lower maintenance costs, and increase equipment safety by identifying and preventing potential problems through condition-based maintenance programs. 


  Irving Paper, New Brunswick, Canada  
 

Irving Paper implemented a highly successful condition-based asset management system based around the PI System.

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