Shandong Bohui PM 8 and Valmet: Automation drives a new level of quality productivity

Shandong Bohui PM 8 is the flagship project of Bohui Paper (stock code: 600966), a listed company of Asia Pulp & Paper Co., Ltd. (APP), at its base in Shandong. It is also a critical element in the blueprint of Bohui Paper’s strategic development. It is one of the fully Valmet-supplied complete large-scale graphic paper production lines, including a complete production line from stock preparation to the reel to the winder, as well as a complete automation and Valmet's Flow Control solutions. The highest operating speed was 1,750 m/min in September. The overall equipment efficiency (OEE) was maintained at a higher level in the industry, and the products have gained widespread customer recognition and continue to lead the premium market segment.

The project began construction in early 2022 and successfully achieved first-time paper production on October 9 of the same year. Throughout the project, Shandong Bohui established a close partnership with the Valmet team to overcome the challenges of the pandemic and ensure the project’s smooth progress.

The complete automation package for PM 8 was supplied by Valmet, including the Valmet DNA Distributed Control System (DCS), the Machine Control System (MCS), the Valmet IQ Quality Control System (QCS), Valmet DNA Machine Monitoring (DMM), Web Monitoring System(WMS), the Paper Lab Analyzer, and Flow Control solutions. Sun Shixiang, Deputy Director of the Engineering Department at Shandong Bohui Paper Industrial Co., Ltd., comments: 

Simplified operation and training: All systems (such as DCS, MCS, and QCS) utilize the same operator interface, system tools, and hardware, allowing operators to quickly master all the systems’ operation methods. This not only reduces training time and costs but also increases efficiency.

Enhanced system integration: The unified platform allows smoother data sharing and communication between systems, ensuring that all aspects of the production process work seamlessly together. The high level of integration optimizes the production process and reduces delays and errors in intermediate processes.

Improved system stability: Systems running on the same platform enable better coordination and management of all aspects, reducing compatibility issues between systems. Valmet’s unified platform ensures high equipment stability and reliability, reducing failure rates and downtime.

Easy to maintain and upgrade: Maintenance personnel only need to master the maintenance method of one platform to maintain and manage all the equipment. In addition, system upgrades can be performed simultaneously, reducing downtime and maintenance costs. Staffing needs are also reduced.

Centralized data management: Data from all systems is consolidated on a single platform, facilitating unified data management and analysis. Through centralized data management, Bohui Paper can monitor the production process better, identify and solve problems in a timely manner, and improve production efficiency and product quality.

Improved security: The unified platform with its consistent security policies and protection measures can protect the system more effectively from external threats. Valmet DNA automation system excels in security in today’s environment of frequent cyberattacks, ensuring the safe operation of equipment through rational interlocking configuration and fault localization.  

Valmet’s DMM system has played an important role in Shandong Bohui’s PM 8 project. The DMM system monitors the equipment’s operating status in real time to detect potential issuesin a timely manner. By analyzing real-time data, Bohui Paper can take quick action to prevent problem escalation and reduce downtime. The DMM system also enables Bohui Paper to carry out preventive maintenance, identifying and solving equipment problems in advance to avoid sudden breakdowns. This not only improves the equipment’s operational stability but also extends its service life. As a result, it has helped Bohui Paper reduce unnecessary maintenance work and downtime, and maintenance costs. Through accurate fault localization and timely maintenance, Bohui Paper can manage its equipment more efficiently and save a lot of resources.

Another highlight of PM 8 is that it is equipped with a Valmet Paper Lab analyzer. The Valmet Paper Lab is an automated mobile “laboratory” for paperboard and paper quality analysis, enabling comprehensive verification of paper product quality. The highly automated testing process provides more authentic and reliable data to guide production optimization, helping Bohui Paper control product quality more accurately and meet customer needs. The Paper Lab analyzer provides a solid foundation for Bohui Paper’s future smart manufacturing. Through comprehensive data collection and analysis, Bohui Paper can achieve higher levels of automated and smart manufacturing and improve overall competitiveness.

In addition to the automation system, Valmet Neles valves and matching positioners, totaling 170 units, were used in Shandong Bohui’s PM 8 project. These valve products have performed exceptionally well in the project’s vacuum and stock flow systems, greatly enhancing production efficiency and system stability.

Hou Donghai, Chief of the PM 8 Engineering Department of Shandong Bohui Paper Industrial Co., Ltd., says that despite the multiple challenges the project faced during the pandemic, Valmet’s team delivered the equipment on time, ensuring uninterrupted installation progress. Especially in the equipment installation and commissioning process, Valmet’s support team exhibited exceptional professionalism and responsibility. They completed the integrated commissioning from individual units to full machine coordination in only 15 days, achieving successful paper production – far exceeding expectations.

In a vacuum system, Neles valves can precisely respond to pressure fluctuations, which ensures the system’s stability and avoids the quality problems that may occur in the production process. In the stock flow system, Neles valves’ high precision and maintenance convenience are also highly recognized, greatly improving maintenance efficiency and ensuring the system’s continuous and stable operation.

Valmet’s aftersales service team provided comprehensive support for Bohui Paper, from project commissioning to subsequent stable operation. Valmet’s team members have visited the site several times to provide technical guidance and training to ensure that Bohui’s young team can master the relevant technology and guarantee the smooth running of production. Hou Donghai particularly praises the rapid response and professional support of Valmet’s team, which made the implementation of the entire project efficient and smooth, and the valves always operated stably and without problems.

The automation and flow control solutions provided by Valmet delivered significant advantages to Shandong Bohui’s PM 8 project. These systems have not only improved productivity and product quality but have significantly reduced maintenance costs and downtime, providing a solid guarantee of Bohui Paper’s success. Valmet’s professional team and high-quality equipment have ensured the project’s smooth implementation and long-term stable operation, and the cooperation between the two parties will continue to promote the common development of the business.