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Zero tolerance against grammage
variations in board production
Catherine Östlund
Innventia
This is a copy of our presentat...
www.innventia.com © 2015  2
 Research Institute
– Owners: direct and through associations:
Industry 71%, Government 29%
...
www.innventia.com © 2015  3
Our RD&I covers several value chains
 Pulp, paper and board production
 Printing and media
...
www.innventia.com © 2015  4
Innventia develops and optimizes paper processes
Paper processes
The FEX machine is developed...
www.innventia.com © 2015  5
Is there a need for more measurements?
Figiel, K. et al: Paper Machine Quality Control System...
www.innventia.com © 2015  6
Up to 1 km2 produced area per hour!
Visual image
IR image
FTP Partnering Event 2015,
27 Octob...
www.innventia.com © 2015  7
What does the paper and board industry need in 5 to 10
years?
 A product produced using less...
www.innventia.com © 2015  8
 ”Total area in real time”:
measure all produced area
 ”Measurement and analysis in multipl...
www.innventia.com © 2015  9
High resolution online measurements
IR, NIR and visible wavelengths
- Online surface structur...
www.innventia.com © 2015  10
High resolution online IR
measurements
IR to correlate temperature
after dryer to
• grammage...
www.innventia.com © 2015  11
Three levels of implementation
1. Expert system for troubleshooting/mapping
Identification o...
www.innventia.com © 2015  12
Measurement and analysis principle
IR data
QCS data
Grammage
analysis
FTP Partnering Event 2...
www.innventia.com © 2015  13
 Licentiate thesis, “IR Emittance of Paper” Caroline Hyll, Royal Institute of Technology, K...
www.innventia.com © 2015  14
Step 1
Initiation
Project goals
Step 2
Pilot
implementation
Step 3
Permanent
implementation
...
www.innventia.com © 2015  15
Thank you for listening!
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Zero tolerance against grammage variations in board production

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This is a copy of our presentation of a project idea at the Innovation track at FTP partnering event in Münich in October 2015. I have added speech bubbles to guide you through the slides. Please feel free to contact me if you have questions and comments: catherine.ostlund@innventia.com

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Zero tolerance against grammage variations in board production

  1. 1. Zero tolerance against grammage variations in board production Catherine Östlund Innventia This is a copy of our presentation of a project idea at the Innovation track at FTP partnering event in Münich in October 2015. I have added speech bubbles to guide you through the slides. Please feel free to contact me if you have questions and comments: catherine.ostlund@innventia.com
  2. 2. www.innventia.com © 2015  2  Research Institute – Owners: direct and through associations: Industry 71%, Government 29% – A no dividend organization  Commissioned Research: – Exploratory research often with governmental funding – Innventia Research Programme with several partners – multi client – Bilateral single client projects  In close collaboration with: – Other institutes – Universities – In EU funded projects Innventia - Boosting business with science Innventia provides innovative ideas and scientific research results focused on wood-based raw materials for clients along the entire value chain FTP Partnering Event 2015, 27 October, 2015, Münich, Germany First three slides describing our research institute, and parts of what we do. More information about us can be found at http://www.innventia.com/en/
  3. 3. www.innventia.com © 2015  3 Our RD&I covers several value chains  Pulp, paper and board production  Printing and media  Packaging and the supply chain  Bioenergy, chemicals and biomaterials  Testing, optimising and prototyping  Sustainability, CSR and LCA-analyses  Grants office and Library services FTP Partnering Event 2015, 27 October, 2015, Münich, Germany
  4. 4. www.innventia.com © 2015  4 Innventia develops and optimizes paper processes Paper processes The FEX machine is developed with a flexible pulping system Pilot paper machine FEX is to research tools that enable testing under realistic conditions of theories for materials and process technology development Innventia developed stratified forming which reduces energy consumption and improves product features FTP Partnering Event 2015, 27 October, 2015, Münich, Germany This is our pilot paper machine FEX, were we will try out our proposed measurement system which I describe in the following slides.
  5. 5. www.innventia.com © 2015  5 Is there a need for more measurements? Figiel, K. et al: Paper Machine Quality Control Systems (QCS), Vol1: Measurement systems and Products Variability, Tappi press FTP Partnering Event 2015, 27 October, 2015, Münich, Germany This is how we want to do it. This is the way many measurements are collected today.
  6. 6. www.innventia.com © 2015  6 Up to 1 km2 produced area per hour! Visual image IR image FTP Partnering Event 2015, 27 October, 2015, Münich, Germany Yes, that is A LOT of paper…
  7. 7. www.innventia.com © 2015  7 What does the paper and board industry need in 5 to 10 years?  A product produced using less energy & less raw material  Not necessarily always a better produced quality - but a more even quality  A more flexible production – and the tools to achieve that FTP Partnering Event 2015, 27 October, 2015, Münich, Germany This is what the paper and board industry tell us when we talk to them about the near future.
  8. 8. www.innventia.com © 2015  8  ”Total area in real time”: measure all produced area  ”Measurement and analysis in multiple wavelengths, also outside the visible interval”: Multisensor/multispectral measurements and analysis to gain more information – Combination of different information  IR to correlate drying process to grammage, material variations and dryness variations  NIR for material composition  Secondary properties like surface structure online  Soft sensors  ”Platform”: Create a platform for integrating image based (2D) measurements methods in QCS Ideas discussed at Innventia in workshops with industry, academia and instrument suppliers FTP Partnering Event 2015, 27 October, 2015, Münich, Germany
  9. 9. www.innventia.com © 2015  9 High resolution online measurements IR, NIR and visible wavelengths - Online surface structure measurements (left) and trend (right) measured using online OptiTopo - 5 min temperature variation on tambour induced by a moisture variation (IR) - Classification of material composition in sheets (NIR scanner) Change of coating blade 20 cm 6 m FTP Partnering Event 2015, 27 October, 2015, Münich, Germany At Innventia we have worked with and developed measurement techniques and analyses during many years, and these are some of them that are or can be applied online in a large scale.
  10. 10. www.innventia.com © 2015  10 High resolution online IR measurements IR to correlate temperature after dryer to • grammage, • material variations and • dryness variations 6 m FTP Partnering Event 2015, 27 October, 2015, Münich, Germany The IR camera technique has been studied and used during 6 years in different project at Innventia. The IR technique will be the main tool for measurements in this project.
  11. 11. www.innventia.com © 2015  11 Three levels of implementation 1. Expert system for troubleshooting/mapping Identification of process variations in full scale; throughout paper machine 2. Alarm function: Automatic identification of extreme statistical outliers for a more even production; web breaks 3. Implementation in a QCS; optimisation of process. Alternatives for implementation FTP Partnering Event 2015, 27 October, 2015, Münich, Germany This is what we go for in this project idea
  12. 12. www.innventia.com © 2015  12 Measurement and analysis principle IR data QCS data Grammage analysis FTP Partnering Event 2015, 27 October, 2015, Münich, Germany A short description of the thought analysis: We collect IR data of all produced area. Additional data from QCS is used to calibrate the IR data. The output are maps, curves and trends that are fed back into the process optimisation system to control the quality.
  13. 13. www.innventia.com © 2015  13  Licentiate thesis, “IR Emittance of Paper” Caroline Hyll, Royal Institute of Technology, KTH, Stockholm, Sweden, 2012  IR and NIR measurement case studies for different paper qualities in the previous Innventia Research Cluster program (2012-2014)  Large-scale and long-term studies of temperature variations on two machines during early 2015 (ÅForsk funding)  “Roadmap for implementation of multispectral quality control of the whole produced area in paper and board making” during first half of 2015. (Process Industry IT and Automation (PiiA) Strategic Innovation Programme, Vinnova funding)  “Evaluation of multispectral material analysis for online application in board making”, ongoing project. (PiiA Strategic Innovation Programme, Vinnova funding) Projects at Innventia aiming at developing an online large- area analysis of process variations FTP Partnering Event 2015, 27 October, 2015, Münich, Germany We have already made a great deal of work in projects with these kind of measurements
  14. 14. www.innventia.com © 2015  14 Step 1 Initiation Project goals Step 2 Pilot implementation Step 3 Permanent implementation Project goals Industrial value, Effect goal VisionProject goals A more sustainable society through a better use of wood-based raw material with the help of a higher resource and process efficiency in industrial board production Analysis of needs for measurements of grammage variations in paper and/or board production made Built a consortium of relevant actors from complete value chain IPR regulated Defined plan for implementation of a measurement concept Accomplished total-area measurements in pilot and industrial scale over a long time period Total-area measurements of grammage integrated in a board machine The analysis of measurements are used for optimisation of the process The system is marketed internationally by a instrument supplier An increased process efficiency leads to an increased competitiveness for the board industry A measurement system that can be marketed internationally A more even quality of the paper/board products will lead to new product opportunities Methods developed to handle and analyse data, and implement it in QCS Tools developed to present the variations in a operator-friendly way ” Zero tolerance against grammage variations in board production” FTP Partnering Event 2015, 27 October, 2015, Münich, Germany A proposed project road map for this project idea.
  15. 15. www.innventia.com © 2015  15 Thank you for listening!

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