Valmet DNA for Paper Industry

The best possible payback

 The Best Possible Payback
Every paper, board and tissue maker around the world knows what it takes to meet the
challenges of undisturbed production and cost-effectiveness under today’s demanding
market conditions.
One way to keep up with today’s
rigorous market demands for paper,
board and tissue producers is to up-
date their existing processes regularly
and invest wisely in new equipment
and employee tools as well as the
skills required to meet future produc-
tion challenges.
Automation pays back in
performance power
Increased production efficiency and
cost savings are achievable with the
right measurements, controls and
operator tools. The payback from
automation is measured in increased
performance power gained by re-
duced area losses, reduced idle time
and increased production rates. Cost
savings result from raw material and
energy savings through optimizing a
mill’s processes.
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At Valmet, we ensure the maxi-
mum and sustainable profitability of
paper production lines with accurate,
reliable process and product mea-
surements, stabilizing controls, valves
and other process control devices,
advanced multi-variable process con-
trols, and operator information tools.
With our wide scope of automation
applications, we can supply you with
a feeling of control.
Case:
PABCO saves 14 % fiber,
3% steam, 3% chemicals
A new automation rebuild has paid
off handsomely for the Vernon, Cali-
fornia mill. Product quality variabili-
ty is much improved. Customers rate
the quality as the best ever.
To meet the production needs of
their Las Vegas plant, and to keep
up with their end-user demands for
better board consistency, PABCO
Paper in Vernon, California decided
to invest in improved process and
product quality measurements, pro-
cess stabilizing controls, and vastly
expanded operator information and
decision-making tools from Valmet.
The results from the upgrade are
remarkable: Pabco board automation
now saves 14 % fiber, 3% steam, 3%
chemicals with 26% less customer
complaints.
 It’s in our DNA
Valmet DNA offers paper mills a comprehensive portfolio of automation applications to
stabilize and optimize their paper making processes. Scalable to your mill’s specific pro-
duction needs, Valmet DNA provides you powerful performance through machine, quality
and process controls all in one.
Our wide industry know-how with process and automation experts under the same
roof ensures that all our new innovations will match your industry-specific challenges now
and in the future.

SERVICE

• Process Measure-
Controls • Machine ments
• Quality
• Drives
SER
E
SERVIC

• On-line
VICE

• Valves
• In-line
• Profilers It’s in our • Laboratory
DNA

• Process
• Quality • Condition Asset

Manage-
Actuators • Environment monitoring ment
• Knowledge
SE

i
E C RV
VI ICE
ER S

Information
Management

Fiber consumption

-14%
Steam & chemical
consumption

-3%
End customer
satisfaction

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 Unleash Your Efficiency Potential!
At paper mills, automation pays back through reduced area loss, reduced idle time and in-
creased production rates. Whether an upgrade or the replacement of old systems, Valmet
DNA will give a solid ROI through increased tons and diminished costs.
Efficient process controls help reduc-
ing the amount of broke, as well as
both number and duration of breaks.
Specially designed monitoring sys-
tems enable fast trouble-shooting and
help mills reduce idle time, caused by
for instance web breaks, thus reduc-
ing unplanned shutdowns. State-
of-the-art controls and user tools
also allow for faster recovery from
shutdowns, smoother grade changes
and quicker start-ups –
all benefits that count in efficiency.
A replacement pays back
The benefits from automation are
clear when replacing mills’ existing
systems with modern Valmet DNA
control applications. More reliable
controls will increase availability
and production efficiency. Modern
control applications can also unleash
the unused speed potential of your
machine. The replacements by Valmet
DNA all over the world have proven a
clear ROI.
Take a hard look at the
bottom line
You can see the improved production
efficiency in the bottom line. Even
1%-unit increase in the overall effi-
ciency translates into a big increase in
the profit with a medium-sized paper
production line.
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A farewell to unplanned
shutdowns
Valmet DNA Machine Monitor-
ing provides process operators and
maintenance staff an easy access
to machine condition information
through the same user interface that
is used in process and quality control.
The common view helps operators
and maintenance personnel work to-
gether to detect and solve developing
mechanical problems.
Valmet DNA Paper Reel
Quality Monitoring
The DNA Reel Monitoring allows
operators to receive, see, use, present
and share quality information from
online and offline paper reel quality
measurements. By providing visual-
ized paper web sheet quality infor-
mation it helps improve production
and quality efficiency, and maximize
sellable product with accurate and
continuous quality monitoring of
machine reels.
It’s in our DNA.
Winder controls – a new
member in our application
family for the paper industry.
Effective winder automation
increases the efficiency of your
winder process.
Case
A newsprint
modernization
pays off
The challenge of replacing
systems from several suppliers,
often with outdated technology,
needs to be met with as little
disruption to production as
possible. Aylesford Newsprint
faced the challenge successfully
with Valmet.
For John Godsal, machine
superintendent, a key element in
the migration was the prepara-
tion of functional descriptions
for the operation of each loop
in the system. “The functional
description not only enables the
engineer to program each loop,
but also provides the operator
with a concise description of
what the loop does”, he explains.
The system migration also al-
lowed the mill to “de-clutter” the
existing controls, removing un-
necessary functions that produc-
tion personnel no longer found
useful or did not use. Sequences
on the old system were problem-
atic and the mill has been able
to rewrite these knowing that
Valmet DNA is robust enough to
run them. “Today the only time
they fall over is with plant failure
rather than a control system
failure, as in the past.”
A Window into Your Process
Valmet DNA is the operator’s window into the papermaking process and equipment. Its
user interface and versatile tools have been designed with users in mind – enabling them
to have the feeling of control over their work.

Valmet DNA offers paper mills a UPM Shotton mill in England

Case
Visualization shows
problems faster at
Mondi
Mondi Neusiedler in Austria re-
placed their old PLC controls at
the size press with a state-of-the-
art Valmet DNA system with an
operator interface featuring a
touch panel. The benefits of the
modernization have left no room
for doubt.
Before the control system
rebuild, there was no visualiza-
tion of the sizing process. Now,
the full functionality of the size
press is handled by a touch pan-
el. All the information needed,
including interlockings, trends,
control functions and alarms,
are shown in the process pic-
tures on the panel. This informa-
tion enables the operators to get
a better overview of all size press
functions and notice possible
process problems very quickly,”
says Automation Manager An-
ton Oberleitner.
According to the mill, the
rebuild has increased process
uptime through shorter start-up
and shutdown times. Also, trou-
bleshooting is definitely easier
than before. The users especially
appreciate the many tools, such
as the monitor and interlocking
windows, as well as the trend
and alarm descriptions, which
make the complex size pressing
process easy to operate.
single system that fulfills all the mill’s
process control needs from basic to
advanced controls and optimizing
solutions, and process information
management. Many of its diverse
tools and user interface functions
have been specially developed to
fulfill the paper mill operation tasks
and to help the mill operators succeed
in their work.
Perfect timing
Troubleshooting is often a matter of
correct timing and sometimes the
right action is just a mouse click away.
Valmet DNA provides paper makers
with special tools for advanced prob-
lem solving and efficient disturbance
management.
DNA Help for immediate
assistance
DNA Help is appreciated by paper
mills around the world.
Better Process
overview uptime
Shut-
downs
reports their satisfaction:
“DNA Help has been particularly
helpful in diagnosing machinery halts
which previously needed the diagno-
sis of a technician. Now operators can
identify the specific causes of a halt
themselves. The mean time to repair
is definitely better.”
A Finnish customer emphasizes
the importance of DNA Help for
machine controls in the integrated
system: “It helps operators to detect
what has happened and why,” the mill
comments on.
Feeling of control. In trouble-
shooting, the right answer can
be just a mouse click away.
DNA Help guides operators
to take the correct actions
quickly enough.
It’s in our DNA.
 Cost Savings from Stable Quality
Struggling with today’s demands for cost-effectiveness, paper mills can hardly afford
quality mistakes. More stable quality can be leveraged to give impressive savings through
reduced raw material as well as chemical and steam or energy consumption. Not to men-
tion, what insufficient quality costs for the business.
Stabilizing and optimizing the
papermaking processes can result
in remarkable raw material savings.
Applying dewatering and drying
energy to the paper, board or tissue
sheets enables maximum thermal ef-
ficiency and cost savings. Automation
solutions are also labor saving, thus
making sampling and testing hands-
free operations. Additionally, reliable,
self-diagnostic measurements con-
siderably lower the lifecycle costs of
analyzers and automation equipment.
Valmet DNA Paper Cost
Monitoring
Rising energy prices and new en-
vironmental requirements create
challenges for tissue producers. The
Valmet DNA Paper Cost Monitoring
application is a tool for optimizing
the energy consumption of the paper
production process. The real-time
displays for energy usage and costs
give a detailed view as to when and
where the energy and its related costs
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are being used. Historical reports in-
clude a variety of tools for the analysis
of energy consumption for a certain
time period, paper grade or produc-
tion rolls. The real-time monitoring
of energy consumption and costs help
operators tune the energy efficiency
of the process.
Extended lifecycle and
minimized costs
Upgrading the capabilities of existing
automation infrastructure, allows for
less maintenance costs and maxi-
mized uptime. As a result, you can
extend the lifecycle of your auto-
mation investments for many years
ahead. Also, with a more capable
automation platform, you can add
several optimizing controls for extra
return on investment.
Perfect balance between
efficiency and quality
Optimization of de-inking processes
is a necessity in terms of operating at
the best balance of production, quali-
ty, cost and environmental needs.
The Valmet RCF optimizer
solution facilitates optimization by
providing key performance measure-
ments, with coordinated control of
production, furnish brightness, eric
and ash content. The solution also
incorporates realtime optimizers
orchestrating the operating targets to
meet multiple simultaneous objec-
tives such as, maximizing produc-
tion, maximizing yield, minimizing
chemicals, operating at acceptable
quality while respecting all limits and
constraints of the process.
It’s in our DNA.
A standard for quality, Valmet
IQ provides a state-of-the-
art quality control system
for paper production lines,
using the same user interface,
engineering tools and com-
mon spare parts as the Valmet
DNA automation system.
Yield Process Chemical
stability costs

Environment as a Good Business
Eco-efficiency requirements keep tightening everywhere around the globe. The demand
for better environmental performance affects both the mill’s economy and image.
Valmet DNA includes a wide se-
lection of control and information
applications that help paper, board
and tissue makers to make their
production processes more green and
profitable – all at the same time. The
improved image of the entire industry
is an extra asset.
Case:
The world’s northernmost
paper mill relies on model
predictive controls
Stora Enso’s Veitsiluoto Mill man-
ufactures office papers and coated
mechanical papers in Kemi, Finland.
The steam network of the northern-
most paper producer in the world is
successfully controlled with Valmet’s
multi-variable model predictive con-
trol system.
Costs Pressure Need to
controls burn oil
“The fact that all components
can be employed in pressure
control means less reliance on
uneconomic pressure reduc-
tions, auxiliary condensers and
the need to burn oil”
- Pekka Nykänen
The aim for the model predictive
controls is to maintain stabilized
steam network conditions at all
pressure levels, as well as to minimize
energy losses. The model predictive
controller is integrated within the Ve-
itsiluoto Mill’s Valmet DNA automa-
tion system. Also the user interface is
seamlessly integrated into the plant’s
control displays.
The integrated system provides
automatic management of big load
changes, thus freeing operators
for more important tasks. Pekka
Nykänen, Operations Manager at
Veitsiluoto’s power plant, says that
they can now achieve better pressure
control with less steam accumulator
consumption, which also means less
costs. “The fact that all components
can be employed in pressure control
means less reliance on uneconomic
pressure reductions, auxiliary con-
densers and the need to burn oil” says
Nykänen enthusiastically.
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 Valmet’s professionals
around the world work close
to our customers and are
committed to moving our
customers’ performance
forward – every day.

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© Valmet Corporation, BR81440_EN_01, 07/2015.

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