Pulp & paper industry

Solution design

Pesmel’s solutions have been expertly designed and engineered to serve the needs of each individual customer. Tailoring is essential due to variations in production parameters and mill site preconditions as well as end customer needs and requirements. We work in close cooperation with our customers and plan functional, highly automated solutions for both brownfield and greenfield projects. All systems are designed according to the latest safety regulations.

Feasibility study

Real-life situations and conditions at the site are simulated using 3D models of planned or existing production. This is done to understand and analyze operations and identify potential bottlenecks. At the end it will help us optimize the mill layout and our customers to make the correct investment.

Process simulation, part of the feasibility study, allows us to anticipate situations that we could not otherwise prepare for. The adaptive model can be manipulated to simulate exceptional situations or possible future needs. Logistics and buffering functions as well as guidelines for the control system can also be defined.

Project implementation

Pesmel has more than 40 years of experience in delivering material handling projects. With deep knowledge and insights into the mill processes, material flows and end customer requirements we excel in delivering solutions in mechanics, electric, PLC and ICT. Our in-house experts in engineering and manufacturing fulfill the highest international standards and country-specific quality criteria.

As a total system supplier Pesmel takes overall responsibility for the project from pre-engineering to hand-over. Project implementation includes full equipment and system engineering, manufacturing, assembly, testing and commissioning, and work safety is of prime importance throughout the project. We also offer comprehensive training for operators upon commissioning and throughout the lifecycle of our solution. Full documentation is always included in the delivery.

Automated handling of paper rolls and pulp bales

Pesmel conveying systems cover transportation inside the mill. All systems are engineered based on an understanding of how the products, whether paper rolls or pulp bales, need to be handled. Intelligent and fully automated functions ensure smooth and damage-free material flow everywhere between production and shipping.

Our range of material handling includes conveyors and systems for sorting and loading. Sorting is done through sorting bins, a fully automated high bay storage or through a combination of different handling methods.

Efficient automated packaging

Pesmel’s packing lines are designed to provide immaculate protection against the elements and damages in handling and transportation while at the same time optimizing the usage of packaging materials. A high degree of automation reduces the need for manual labor and the risk of human error.

Our packaging lines are modular in design making them adjustable to meet prevailing requirements. Each customer’s needs, such as space considerations, capacity and packing code requirements are taken into consideration. Our packing systems all have fully automated functions with high capacities up to 180 rolls/hour/line. Our compact wrapping lines can be complemented with attachments such as weighing, labeling, lid insertion, palletizing and binding/strapping units.

Selecting the right packaging line

Kraft wrapping has long been the dominant packing method in paper mills for printing grades while stretch film wrapping in all its variations has been the main method for tissue, fluff pulp, specialty papers and internal dust and moisture protection for rolls destined to be sheeted. However, the selection of packaging method is not always straightforward. We look at each new case individually, utilizing simulations to identify the appropriate solution.

Our kraft wrapping systems are of Valmet Optiwrap type, provided by Pesmel as contract supplier. For more detailed product information, please see OptiWrap.

The intelligent storage solution

Pesmel’s unique high bay storage solution delivers unparalleled capacity, accuracy, safety and reliability through advanced automation. A well-planned solution reduces the footprint of the storage facility in both greenfield and brownfield projects, both in and outside existing buildings. The system keeps track of the inventory and reduces risks related to manual storage and handling. The storage is integrated to the mill process providing high automated efficiency and availability without bottlenecks.

The WMS (Warehouse Management System) controls material flow between different processes, optimizing storage and logistics functions, for fully automated inventory control and decreasing operational costs. Load handling is automatically carried out by stacker cranes, each with a capacity equivalent to 4-6 clamp trucks. Loads are gently handled from the bottom and stored in racks, all of which ads to efficient and smooth overall operation.

Unlimited capacity

Pesmel’s storage solution, TransRoll® for paper rolls and TransBale® for pulp bales, is especially well-suited for high sorting needs for mixed production. The solution can handle pulp bales, rolls or roll sets without limitations related to dimensions or packing variants. Rolls and bales can be unwrapped, partially wrapped or fully wrapped.

The handling and sorting capacity of the TransRoll® solution is virtually unlimited. All together the roll stream in and out can reach up to 400 rolls/hour/stacker crane. Storage is fully adjustable along all three axes; length, width and height. Due to system and design flexibility it is suitable for both new and existing mills.

The TransBale® solution for bale handling and storage allows storage racks up to 15 units high. Bales are handled from the bottom which makes it possible for the system to cope with differently sized and shaped loads. Storing on racks rather than on the floor allows significant increases in storage density.

The Pesmel Material Flow How® concept does not only cover our automated solutions but support and services across the process lifecycle. A comprehensive service agreement ensures availability through regular maintenance operations as well as fast troubleshooting in unforeseen circumstances. Minimizing the risk of unplanned and expensive downtime is a part of our service ethos.

Maintenance

Regular maintenance guarantees high availability and extends the lifetime of the system. Preventive maintenance minimizes unexpected repairs and helps to keep total investment and operational costs in balance. Regular checks and adjustments ensure reliable operation. Maintenance breaks can also be used for optimizing the processes.

HelpDesk

Our HelpDesk service is there for our customers 24/7 ensuring reliable performance of the process and equipment. A HelpDesk service contract will provide constant access to expert assistance whenever needed. Our specialist will help the customers over the phone or set up remote access to the control system to directly assist in troubleshooting.

Spare parts

We provide comprehensive spare part services for material handling systems. Spare and wear part recommendations are made for every delivery project. Pesmel’s spare part services guarantee the latest, best quality spare parts available.

Upgrades

Frequent upgrades can help extend the lifetime of a process and the profitability of the original investment. Our research and development, focused on material flow how, not only generates innovative process solutions but a variety of cost-effective upgrade packages. The packages include solutions that increase system throughput and capacity or improve operational safety, or they can be software upgrades to the control system.

FlowCare

FlowCare is a remote supervisory and preventive maintenance solution for production facilities. The solution monitors the performance of all Pesmel equipment. Important data is visualized in a web portal that can be easily viewed on a computer or any personal mobile device. The custom-built portal allows creation of various types of reports, including periodical reports, which can be sent out via email. This online service product is built with security and user-friendliness in mind. FlowCare will provide valuable insight into the performance of the Pesmel solution, helping identify risks and avoid expensive unexpected repairs. The FlowCare solution puts the entire customer support in our customer’s pocket, 24/7.