The new efficiency concept consists of three elements, and the iRoll soft reel drum is the most important one. It is the world’s first intelligent roll that measures nip pressure and the parent roll profile automatically online. It collects the data with sensors that are located under the soft roll cover. From there, the data is transmitted wirelessly to the control system and can be utilized in controlling the profiles on the calender. iRoll complements or replaces the existing caliper measurement. It can also be used to replace traditional manual hardness measurements on the parent roll.
The intelligent reel drum benefits the papermaking process significantly. It improves wind-up control, which, in turn, improves the parent roll structure, making it 100% tighter and decreasing the amount of air in it. iRoll decreases bottom broke and thus increases the amount of saleable product. It also adds to reel runnability and improves paper quality. The intelligent reel drum is suitable for reeling all paper and board grades.
The IQInductionPro profiler on the calender is the second element of the efficiency concept. It increases paper gloss and smoothness by 10–30% as well as improves the profile by 50%.
The third element is IQWebCD, a model-based multivariable control for cross-direction profiles, which features closed loop control for calendering. It is able to take into account the interactions between several measurement profiles and CD profilers in the areas of the calender and the reel. In this way, it is possible to reach the profiles faster than with traditional control algorithms, and without any dependency on operators or shifts.
Increasing efficiency in the paper machine dry end will take just a short time and can typically be carried out during a three-day shutdown. The investment has a short payback time since it improves paper printability, enhances dry end runnability and decreases bottom broke.
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