Elevating fiberboard production efficiency with Valmet Gap Optimizer

In fiberboard production, woodchips are broken down into fibers through a mechanical process using a defibrator. The quality of the fibers directly impacts the strength, smoothness, and overall quality of the final product, making the defibrator an essential component in the fiberboard manufacturing process. 

Valmet Gap Optimizer is an automated solution designed to control the defibrator disc gaps quickly and accurately. With precise gap management, mills can improve their product quality, extend segment lifetime, and increase overall production capacity. In addition, the system offers the possibility to reduce the defibrator’s specific energy consumption, resulting in meaningful cost savings. 

“We introduced Valmet Gap Optimizer to the market about two years ago and have since delivered the modern defibrator control system to more than ten mills in Europe and North America, including several fiberboard and paper mills as well as an insulation board mill and a soil fertilization production unit. Thanks to the great results – from lower production costs to improved product quality – the solution is becoming increasingly popular especially among fiberboard producers worldwide,” says Liam Ahern, Global Product Manager, Mechanical Pulping and Fiberboard at Valmet. 

Valmet Gap Optimizer comes with a complete package including the hydraulic block, mounting plate and cover, cable assembly, hydraulic hoses and fittings, and assembly and user manuals. 

The installations have been successful, and the customers have been able to, for example, optimize specific energy consumption, reduce maintenance costs thanks to longer refiner segment and bearing lifetimes, and improve product quality. They have also experienced increased defibrator availability due to less unexpected downtime. Valmet Gap Optimizer has proven to be a financially sound solution with a fast payback and high return on investment. 

“The figures really speak for themselves. In various installations, shive reduction has been up to 50%, energy reduction up to 20% and increased segment lifetime up to 50%,” Liam Ahern summarizes. 

Tailored solution to meet customer needs 

As an OEM (original equipment manufacturer) solution, Valmet Gap Optimizer includes self-test functionality, automatic segment calibration, safety diagnostics tools, and plate clash protection system, all contributing to easier operation and improved safety. The installation also comes with a remote connection capability for real-time process support from Valmet Performance Center, along with standard spare parts for simple maintenance.  

“The performance improvements our customers are seeing with Valmet Gap Optimizer have been extremely encouraging, and we’re more than ready to discuss its benefits with any mill exploring control system modernization. For us at Valmet, it’s never just about supplying equipment – it’s about working together to ensure the customer’s production line performs at its best throughout its entire lifecycle,” Liam Ahern says.

The figures really speak for themselves. In various installations, shive reduction has been up to 50%, energy reduction up to 20% and increased segment lifetime up to 50%.

Control system options include a small local cabinet with a touch screen installed close to the refiner. 

The system has a modular design (Gap Control Module unit) and can easily be retrofitted into existing control panels and for easy replacement of older control systems.

Click here to watch a video on Valmet Gap Optimizer and learn more.