CD PROFILING WORLD PULP&PAPER 46 been reduced by over 50%. Profile 2-sigmas are as low as 0.6% - considerably better than the typical industry benchmark of 1% for CD control performance. CD grammage improvements often have a “knock- on” impact on downstream process operations, and this case is no exception. Before the CD weight control, the control range of the calender was limited, but it became more controllable afterwards, leading to improved caliper and surface finish profiles. Quality rejects are down by 10%. CASE STUDY 3 IMPROVING RELIABILITY, CUTTING LOSSES While some papermakers have seen the benefits of moving from manual to automatic control, others may need to tackle profiler reliability problems that come with age. Also, a supply of spare parts to keep them running may be hard to find. For example, Swiss Quality Paper in Balsthal, Switzerland recently started up a replacement cross-direction slice actuator system on PM3, with 42 motorised actuators and control cards supplied by Tasowheel Systems. As shown in Figures 3 and 4, the system server interfaces to the existing QCS system through an OPC link. The 23,000 t/y PM3 produces specialty papers for adhesive tapes in different colours and shades, fine paper for cigarette filters and hygiene papers. The new actuators replaced aging twenty-year-old actuators, originally supplied with the headbox in 1996. They were no longer operating trouble- free and were causing production losses. The start-up in January 2018 was successful in solving the profiling problems whilst also eliminating the production losses. Mill personnel estimate the return on investment will have a payback period of twelve months. CASE STUDY 4 DILUTION VALVE PLUGGING ELIMINATED In some upgrade cases, less is more. For example, Papier und Kartonfabrik Varel in northern Germany wanted to improve CD profiling by upgrading from manual to automated dilution control on board machine KM3. This was part of a headbox modernisation project. The dilution valves are now flushed automatically in groups, which helps to prevent congestion. With plugging in the valves eliminated, production breaks have been reduced. The improved profile control makes the stacking of the sheets on pallets better. That, in turn, is beneficial for transportation. By installing only what was needed, Varel was able to save on costs and also space. CASE STUDY 5 STEAM PROFILER UPGRADED During the latter part of 1990s the market for steam profilers was at its peak, but many of those original investments are now starting to show their age. Some actuators are failing at an accelerated rate and the cost of maintenance is getting high. Tasowheel now offers a solution for those ageing profilers to bring their performance and reliability up to an expected standard. Most importantly for papermakers, a retrofit actuator Figure 5. Original steam profiler actuators. While some papermakers have seen the benefits of moving… to automatic control, others may need to tackle profiler reliability problems that come with age.