How to improve quality?
Better quality for a brighter future
Quality issues are high on the agenda of every paper and board mill, as optimal quality needs to be produced at the lowest possible cost. Valmet offers a wide scope of solutions and services for better end-product quality, from stock preparation to finishing. Stabilizing running processes in all phases of the process leads to cost-effective quality improvements that do not require major investments. We and our customers share the same targets: optimal quality at the lowest possible cost, consistently in all shifts.
Finding the root causes of poor quality
Valmet’s experts perform paper structure analyses that offer insight into disturbances in quality issues. Fiber orientation, formation, curl, bulk, smoothness, gloss and other quality factors are evaluated in laboratory conditions, including benchmarking and recommendations.
Better quality starts with stock preparation
Quality improvements in stock preparation do not just result in better stock quality – they also lead to energy savings and improved production efficiency. All stock can be treated more evenly with Valmet’s refining concepts, such as OptiFiner Pro. This high-capacity refiner provides the same or improved strength properties with lower costs. The enhanced bonding ability of the fibers improves paper machine runnability, resulting in better printability, fewer web breaks, and a uniform refining result.
Lost quality levels can be reinstated and profiles restored in a cost-effective way with Valmet’s headbox maintenance. Our headbox services provide a stable basis weight and even profiles throughout the production line, also improving end-product quality.
Improved formation for better quality
In the forming section, paper and board quality can be effected through furnish optimization and more uniform profiles, as well as improved strength and formation properties. If the target quality can be produced using cheaper furnish, the results are visible in the bottom line.
High surface quality all the way to finishing
Surface sizing, coating and calendering are the steps that can affect paper and board properties such as brightness, smoothness, uniformity, gloss, and opacity. Sizing and coating rebuilds are often used to enhance quality. The rebuild solution and scope depends on the desired goal. Calendering rebuilds are great opportunities for improving quality for all paper and board grades through better profiles and higher temperatures.
Good end product quality can still be spoiled by an uneven winding of customer rolls. Ragged cuts cause unnecessary customer complaints and uneven quality. Reliability, minimized surface core waste and excellent roll runnability in winding can be achieved with winder modernizations.
Valmet’s unique three-layer headbox and metal belt calender have helped Sappi Maastricht Mill to produce outstandingly white and bulky board, with excellent printability and surface properties.
Sappi's Gratkorn mill rebuilt their PM11 to improve the printing paper quality. The rebuild concept was optimized for improved formation and printability and reduced two-sidedness and validated in the series of pilot trials at Valmet facilities.
Frequent customer complaints regarding the evenness and CD profiles of Dongguan’s linerboard led Yinzhou Paper to replace the headboxes and invest in modern quality control system.
The first OptiFiner Pro refiner in Southern Europe started up in Cartiere Ermolli mill in 2014. The new refiner replaced two existing refiners at PM 1, increased the overall refining capacity significantly and reduced energy consumption by 20%.
New system delivered a boost in quality and an increase in productivity at Smurfit Kappa’s Ania board mill, when the mill replaced an aging system on BM3 with Valmet IQ.
The forming section rebuild with Valmet's shoe blade technology improved formation and reduced filler two-sidedness at Sappi Somerset PM3 at Skowhegan, USA. The use of expensive wet end and coating materials were significantly reduced.