Unlock mill-wide efficiency with Valmet Digital JumboRoll™

In many tissue mills today, tissue making and converting can operate as two different departments, each with its own targets, tools, and view of the process. The paper machine team pushes for maximum production and troubleshoots from a machine perspective. Converting does its best with the reels it receives, sometimes good, sometimes frustrating. Both teams are skilled, both are committed, and yet neither has ever had the full picture. 

Digital JumboRoll™ changes that. It is an innovation from Valmet that connects these two parts of the operation, making data and knowledge available from end to end. 

A digital twin of every parent roll 

Digital JumboRoll™ is a digital twin of the parent roll. It stores both quantitative and qualitative data about each individual reel and carries that information forward. From the tissue machine, through the warehouse, to the converting line. 

That single innovation unlocks a lot. Mills have always collected large volumes of data on the tissue machine, but it has mostly served machine optimization. Converting has a different need, what is in this reel running right now. Digital JumboRoll™ was built to deliver the data in a format that is genuinely usable downstream, creating a virtual connection between tissue making and converting for the first time. 

From driving in the dark to seeing the road ahead 

Converting has historically run parent rolls without knowing what was inside them. Almost like driving on a dark road without headlights. You don't know whether a curve is coming, or a hole. A break was often inevitable, and speed losses were normal. The operator, not knowing, if he saw a quality problem would slow down not knowing when to go back to normal speed. All these causes could cause an OEE loss of up to 10 percent, and these were simply accepted as part of the process. 

Digital JumboRoll™ turns the lights on. Operators can see defects and variations in caliper and moisture before they arrive, and act proactively. Many actions can be handled automatically. Instead of running into the hole, the operator is in control, slowing down and adjusting. 

Value for the whole mill 

This is where innovation becomes a mill-wide benefit rather than a departmental tool. 

• Converting operators get reel characteristics directly in the control panel, with clear indications of what needs action. A functionality that is already delivered today. 

• Tissue machine operators get early indication of how convertible the rolls they are producing right now will be, so quality decisions move upstream. 

• Process engineers and analytics teams get OEE per reel, reel property visualizations by zone, and runnability prediction. Enabling them to separate good performers from poor ones within the same production context, understand how caliper profile combinations affect converting speed and runnability, and trace where broke is really generated. 
• The mill as a whole gains a common language between assets. A mill is a complex system of machines that must work in a coordinated way. Shared data is the foundation for that coordination and an important step on the path toward the autonomous mill. 

You can now see defects and variations in caliper and moisture before they arrive and act proactively — and many of those actions can be handled automatically." Johanna Pihl, Project Manager, R&D

Closing the loop 

Digital JumboRoll™ closes the loop between tissue making and converting, enabling end-to-end optimization and continuous, shared learning across the mill. By giving both departments access to the same reel-specific insight, it creates a stronger foundation for collaboration.