Real-time strength property predictions for smarter, more efficient production
Valmet IQ Virtual Sensor
Valmet IQ Virtual Sensor, a software-based solution that gives paper and board producers real-time visibility of critical end-product strength properties that have traditionally been measured only in the laboratory. By providing continuous quality predictions, the solution enables mills to maintain consistent quality, reduce fiber and starch costs, decrease energy consumption, and increase overall production efficiency.
Reduce costs by optimizing raw material use and minimizing waste
Secure consistent quality through real-time visibility into product properties
Evaluate changes before applying them with a built-in “what-if” simulator
Seamless integration with Valmet DNA and DNAe – one interface, no cloud dependency
Actionable insights from instant quality predictions
In papermaking, you can’t control what you can’t measure. Traditionally, end-quality properties such as tensile and tear strength, burst strength . This leaves operators to run the machine “blind” until results arrive, increasing operational risk and inefficiency.
To stay on the safe side, operators typically build in costly safety margins to avoid rejected batches, which can mean the loss of tens of tons of product.
Valmet IQ Virtual Sensor closes this gap. By delivering minute-by-minute predictions of key paper properties, such as tensile and tear strength, short-span compression test (SCT), and burst, using the mill’s existing data, the system provides operators with real-time visibility into product quality. Continuously learning from laboratory feedback, it enables proactive process optimization, reduces waste, helps prevent quality deviations, and improves efficiency.
In addition, the built-in “what-if” simulation tool enables operators to test adjustments and instantly see predicted quality shifts before applying any real-life changes.
With this transparency, operators can maintain consistent product quality, use raw materials more efficiently and run closer to target values without large buffers or new hardware investment – ultimately improving mill profitability.
Enhanced optimization with integrated control
As part of the Valmet IQ Quality Management Systems family, the IQ Virtual Sensor builds on more than 30 years of innovation in quality management systems for paper and board production. It combines Valmet’s extensive papermaking expertise and decades of process knowledge with advanced digital tools.
Developed as a Valmet DNA/DNAe-based application, the solution provides a seamless and intuitive user experience. All calculations run locally, ensuring secure data handling without cloud dependency.
Operators can easily view predicted strength properties alongside other quality data from scanners, making it simple to adopt and use in everyday decision-making.
Future-proof by design, the solution can also be expanded to automated closed-loop control with Valmet Advanced Process Controls (APC). This enables even greater process optimization and cost savings.
Unlocking greater value with Valmet IQ QCS
While Valmet IQ Virtual Sensor can be delivered as a standalone solution, its full value shines when combined with the Valmet IQ Quality Control System (QCS). Together, they create a unified quality management environment that no other tools can match.
By pairing real-time virtual predictions with the proven accuracy of Valmet scanners and measurements, mills gain a complete quality picture across the entire machine and tighter control of essential quality parameters. This makes Valmet’s offering a uniquely comprehensive package that enhances process performance, streamlines daily operations and supports long-term profitability.
