Dec 8, 2016 Go with the flow

Blog: Ahead of the pack for South African carton board manufacture

Douglas McCrum
Douglas McCrum
Regional Sales Manager
The face of packaging is changing with the traditional carton board market seeing an increase in the demand for plastic packaging, especially in sectors of the food industry.

To remain competitive in the market place, the way forward for South African-based Mpact Springs Mill was to improve operational efficiencies and product quality, reduce costs and increase output. We were happy to partner with this major packaging manufacturer in reducing its overall operating costs while improving quality and increasing throughput. Meeting their objectives was highly challenging as the complex mill works with recycled fiber to produce a world-class product. 

Mpact Springs Mill differentiates its products from competitors by producing very high-quality board with excellent surface properties, which work to enable excellent aesthetics through multi-color printing and rigidity properties for packaging. 90 % of the fiber used in the manufacturing process is from recycled fiber, which is environmentally friendly and crucial in today’s world. 

Metso valves have helped with the optimization of the mill’s production processes and lowered the entire mill’s environmental footprint. Water conservation, energy, and waste reduction is where Metso’s expertise became a vital component in improving the entire process. 

The challenge of sustainability and efficiency

In order to meet Mpact Springs Mill’s Key Performance Indicators (KPIs) from an operational perspective, the mill had to consider control variability, equipment reliability, time and material efficiencies to achieve a higher level of total efficiency. Further down the line, the engineering department has KPIs regarding the reliability, availability, and sustainability of the equipment. Mpact Springs Mill is a 24-hour operation, running 7 days a week, and therefore avoiding unnecessary downtime is also of great importance.

Almost 90 % of the investment capital spent during the last 3 years has gone towards quality improvement, energy reduction, process stability, and total cost improvement. Mpact Springs Mill was not necessarily looking for capacity, but due to the improved efficiency and the optimization of the processes improved capacity was also achieved. It just goes to show that when you get the basics right, you can elevate the performance to the next level.

Committed to delivering results

Mpact Springs Mill has, over the last number of projects, standardized on Neles valves at their plant. We have been able to assist Mpact Springs Mill to improve efficiencies and reduce any downtime or process variability that may occur due to valve failures. Our valve design is developed specifically for these applications.

We were chosen as the main supplier of valves for Mpact Springs Mill due to our global expertise. The dedication of our team getting to grips with what Mpact Springs Mill needed went a very long way in securing the order. This went from considering the bottom line to set up a dependable backup and support process during the project execution.

The extensive valve order for Mpact Springs Mill included a total of 370 ball, segment, and butterfly valves for on-off and control applications from the Neles product portfolios. The control valves are equipped with Neles ND9000 series intelligent valve controllers, which have the capability for advanced performance and diagnostics.

For the whole story about Mpact Springs Mill, read the article 'Ahead of the pack for South African Carton Board Manufacture' in our Showroom.