Tailored solutions for pulp and paper mills

Pesmel relies on its extensive experience and know-how when providing material handling systems for pulp and paper mills.

The processes in any paper mill can be divided into three main areas: fiber preparation, paper making machinery, and finishing material flow. These work best when they are correctly balanced. In this instance, material flow means everything from the slitter winder deck to the mill’s shipping dock. Paper makers are educated in pulping and paper making process technologies, whereas the finishing material flow is left with less attention. However, material flow-related conveying, packing, and storing operations are internal logistics that are vital for smoothly flowing mill processes. These processes demand a different set of skills; know-how of material flow. We call the concept Material Flow How®.

The key to cost-effective internal logistics is a well-engineered system layout that saves space and minimizes the amount of equipment used. In order to create this, a vision of an optimal system is required as a basis for the material flow layout engineering. A common layout engineering mistake is to place too much focus on details at an early stage by jumping directly to component application. This hinders your ability to see the big picture – what is really needed, and why.

It is safe to say that no two mills are identical, so therefore logistics system layouts are always separately tailored for each mill using base modules. This requires in-depth understanding of processes and engineering, as well as a flexible attitude when searching for the optimal solution. At Pesmel, we are specialized in the creation of layout concepts for paper mill internal logistics, specifically for how material moves inside the mill. Pesmel has developed the concept of Material Flow How® that comprises solutions for roll handling, packing, storing, and dispatching – all combined with tailored engineering.

System engineering of a functional mill concept

The production of goods naturally takes center stage at paper mills, but attention must be paid to internal logistics in order to avoid bottlenecks in the production process. The system engineering of a paper mill begins by defining the must-dos for the internal logistics: specific grade-related handling requirements, the required buffering capacity between production and shipping, packing method selection based on the mill’s actual needs, as well as the preferred automation level.

Pesmel’s cutting-edge solutions

When Pesmel’s specialists make their first visit to the customer’s site, the customer may not necessarily be able to put what they want into words, or even know exactly what they need. The service provider’s sensitivity to interpret the customer’s needs is emphasized in these situations. Pesmel’s specialists have the ability to listen to the customer and, thanks to their expertise in the field, truly understand what they mean. It is easier to start looking for the optimal layout concept when the connection between the customer and the service provider is uncomplicated.

In fact, it is quite common that several layout solutions are possible. Our consultants visit the mill to assess the current situation, as well as envision other possibilities suited to that environment. Pesmel’s advantage is that we can deliver tailored solutions that include all aspects of the mill’s material flow process. We are able to see the big picture and provide the most suitable alternatives across the entire finishing process. Conversations with customers with a genuine understanding are a prerequisite for finding and selecting the most suitable solution for each case. The key is to start this communication early enough, before making other decisions that will limit the number of layout options.

At Pesmel, our 3D illustrations and animations in the concept engineering phase set as apart from our competitor by enabling us to verify and demonstrate solutions in a very tangible manner. Three-dimensional layout concepts are much easier to understand when compared to a stack of 2D illustrations, even for engineers who have spent most of their careers with two-dimensional illustrations. Our 3D illustrations are the first steps on the path to possible full-scale simulations with actual production data. 

A simulation study is a vital tool for assessing the practical situation and planning the layout concept at an early stage of the project. The real situation is simulated with real product measures, capacities, and equipment layouts. This is in order to identify the possible bottlenecks and analyze the total capacity of the mill. With this information, the customer is able to optimize the purchase, often with big savings when it comes to actual machine purchase. A simulation study also gives guidelines as to which kind of roll-handling, packing, storing and dispatching systems should be built. The study also creates a foundation for an upper-level control system, helping to plan and execute it in practice with a production-oriented approach.

Strong and experienced resources

Pesmel’s experts are all in-house, which means the system engineering process is more flexible and easily controlled. All the phases of the delivery – system engineering, manufacturing and assembly of the machinery, as well as installation of the system – are overseen by Pesmel’s own skillful personnel. When the whole system is delivered by one supplier, all parts operate seamlessly together and the production flow can be guaranteed.

Pesmel FlowCare helps in optimizing operations in pulp and paper mills

IoT, the Internet of Things, means the connection between various equipment, vehicles, and buildings that are created with sensors, software, and network connectivity. This makes it possible to collect and exchange data between the various objects and to monitor and control them remotely. The collected data can be refined into usable form through analysis, and different kinds of reports and other resources which help to improve the mill’s production and cost-efficiency can be created.

A paper mill is full of sensors that are controlled by programmable logic controllers (PLCs). IoT makes collecting and analyzing data much easier. For example, the mill’s service manager can use IoT software to identify and anticipate the equipment’s and system’s need for spare parts and maintenance, as well as planning maintenance schedules. Maintenance personnel no longer need to constantly inspect the equipment, which makes their work easier and creates cost savings. In addition, operating expenses are lowered when fewer personnel are needed to ensure the reliability of the mill.

Pesmel delivers the FlowCare IoT software as part of the system delivery. FlowCare is a part of Material Flow How® together with machinery and other equipment, automation, and data systems. FlowCare primarily works in the mill’s internal network and is fully operated by the customer. The software can be downloaded to a smart phone, tablet, or PC, and the customer can use it to follow the operation of any single machine in the mill, the mill’s technical operation, find bottlenecks in production, spot the maintenance needs of the equipment in advance, and optimize the timeliness of maintenance work. The software is intended for the customer’s own use. With FlowCare, the customer can collect and analyze equipment data for operative and maintenance purposes. Pesmel does not collect or use the data collected from the processes and production. Instead the customer analyzes the data and makes their own decisions based on that. This is part of Pesmel’s customer-oriented service.

Pesmel’s Material Flow How

• The ability to understand customer needs
• The ability to find alternative options for the mill layout
• Concept simulations
• Flexible solutions and services
• The solutions cover the whole material flow, from slitter winder deck to the shipping dock
• FlowCare software (IoT) included in the delivery to optimize the operation of the mill