Mills

GLEN ARM, MD , March 1, 2021 (Press Release) -Helios, the new AI and Machine Learning platform tailored specifically to the corrugated converting industry, launched today. The platform is OEM-agnostic and engineered to provide corrugated manufacturers access to robust, actionable insights into the performance of their machines -- enabling minimized downtime, optimized maintenance schedules, and maximized profit. Helios is a product of SUN Automation Group.

“IIoT makes every bit of data actionable,” says Helios Director of Technology Matthew C. Miller. “So many corrugated plants rely on human intuition and experience to drive their decisions. With Helios, anomalies that are imperceptible to even the most well-trained operators can be detected in real time and acted upon. And the machine learning capabilities will mean that the platform only gets smarter the more data and user reactions that it is able to process.”

The new platform is designed to minimize downtime, maximize profitability, and decrease the opportunity cost associated with only taking machines offline for preventative maintenance (as opposed to for major malfunctions). These high-level benefits manifest themselves in specific cost and resource-optimizing operational benefits and actionable insights.

Some of the most beneficial insights are preventative/proactive parts ordering, knowledge about the exact time and cost of parts replacements, the ability for operators to pinpoint the source of slowdowns and other issues, and operator-efficiency training to help machine operators learn and adapt to best practices.

"We understand that data is only as powerful as the actionable insights it can provide,” says Chris Kyger, President, SUN Automation Group. “That's why we are so excited to bring Helios to the corrugated industry. This incredible technology will help box plants increase productivity and efficiency while reducing costs and downtime.”

Helios provides core insights from an accessible, user-friendly dashboard enabling three key benefits: remote monitoring, predictive maintenance, and anomaly detection.

Remote monitoring provides deep insights into current and historical machine operation and performance that can be seen and accessed in real time from any device. Predictive maintenance optimizes machine maintenance intervals using artificial intelligence that adapts based on the machine operation and usage. Anomaly detection notifies users about abnormal machine states that allow operators to react to a potential issue before the failure occurs. More robust predictive analytics will be phased into the platform over time.

Corrugated manufacturers will have access to a free Helios demo, allowing them to experience the platform. The site also provides a Return On Investment calculator that can showcase the benefits that Helios can offer to operations of all sizes and scales.

SUN Automation Group is a corrugated converting industry leader in innovative solutions and aftermarket support and services. Since 1986, SUN has led the way for automated production solutions in the corrugated manufacturing space.

BURGKIRCHEN, Germany, Feb. 22, 2021 (Press Release) -The specialist for automation solutions cts GmbH offers a new, highly efficient robotic solution for the dewiring of pulp bale units in the incoming material area of companies from the "Pulp and Paper" sector. Up to 28 of the bale units weighing tons can be dewired per hour fully automatically with the cts dewiring robot DWR-U. By this, 1 robot can serve 2 or more independent lines in parallel! The flexible robot with electromechanical drives not only saves energy and space, but also protects the pulp from contamination by hydraulic oil. Another benefit: robot-assisted de-wiring significantly increases safety for the employees compared to manually operated motor or hydraulic shears. For the automation specialists at cts GmbH, the robot is a first step in the development of innovative total solutions for automated pulp handling from the incoming material to the pulper or shredder.

Pulp bales are delivered to the processing industry in units of 6 or 8, which are held together with wires running around them. Manual de-wiring of the bale units, which weigh several tons and are often well over two meters high, with hydraulic shears is demanding and power-consuming, and the highly tensioned wires require great care. The previous, classically automated solutions for dewiring, on the other hand, are often inflexible.

Robotic solution increases safety, efficiency and productivity

With the DWR-U, cts GmbH now presents a robust robotic solution that processes all standard market sizes through special mechanical design without the otherwise usual complex pre-programming.

The system, which weighs around three tons, processes bale units up to 1.8 meters length, 1.0 meters width and 2.3 meters height at a conveying height of between 0.8 and 1.2 meters. The flexibilty of the 6-axis industrial robot allows up to 28 bale units per hour to be de-wired for further processing and their pulp bales to be separated on one or two parallel conveyor lines - around the clock, 365 days a year. The robotic-based design also allows customization for 2 or more lines when using an additional traversing axis. Sensors on the gripper unit ensure reliable differentiation and separation of the wiring of the unit and the rewired individual bales. Cut wires are drawn in by the winding unit belonging to the system and rolled up into a tiny, compact coil.

With a connected load of just five kilowatts, the robot operates very economically. Important for the industry: pulp is sensitive and contamination, for example by oil, could render the bales of an entire unit unusable. With its purely electric drive, the robot manages without the use of liquids.

The system is expandable: In a fully automatic line, companies can transfer the bales of the de-wired unit to a second cts de-wiring robot for automatic de-wiring of single bales. This solution can also be combined with the cts winding system for the wires.

Fast, space-saving and flexible to use

Since neither pneumatics nor hydraulics are used, but instead purely electromechanical drives, the DWR-U requires only a small footprint overall. The system is highly standardized. Commissioning and secure anchoring are uncomplicated and also make it possible to retrofit the dewiring robot for the modernization of existing lines.

"With our fully automated dewiring solutions for pulp unit and bale handling, we have made an extremely successful entry into this market," says Peter Mackinger, Head of Software Engineering at cts GmbH. "With the automation of pulp handling via standardized robots, we offer unprecedented flexibility in the incoming material area. We will continue on this path. Before the end of this year, cts will present a smart and trend-setting overall solution. Industrial companies or their plant engineers will be able to obtain everything from cts for the fully automated feeding of pulp bales to the converting process."

About cts GmbH

Founded in 2006, cts GmbH offers a complete range of services for process and manufacturing automation. 350 employees at twelve international locations generate annual sales of more than 72 million euros. The company has already been awarded the coveted Top 100 prize for particularly innovative companies in the German SME sector twice (2016 and 2018).

For the pulp industry, the Factory Automation Division offers comprehensive handling solutions. From the dewiring of the units, their destacking as well as single bale dewiring, over the bale transport which is also possible by means of flexible AMR technology, up to the feeding into the pulper or, by means of sheet separation, into the shredder, cts GmbH provides a comprehensive service portfolio.

In other business areas, cts offers a comprehensive portfolio for visualization, control and monitoring of refinery, petrochemical and pharmaceutical plants. Special attention is paid to the Robotics business area. The range of services here extends from programming and installation to the optimization of welding and production robots or even fully automated packaging systems.

ESPOO, Finland, Feb. 19, 2021 (Press Release) -Valmet and Metsä Fibre, which is part of Metsä Group, have finalized the agreement for the key technology delivery covering all main process islands and automation systems for Metsä Fibre's Kemi bioproduct mill in Finland. The new bioproduct mill will have an annual pulp production capacity of 1.5 million tonnes and in addition produce various other bioproducts. The new totally fossil fuel free mill is scheduled to start-up in the third quarter 2023.

The order is included in Valmet's orders received of the first quarter 2021. The value of the order covering the core equipment supplied by Valmet, is about EUR 350-400 million.

“We want the best professionals in their field to partner with us to build a modern bioproduct mill in Kemi. We expect our partners to commit to the goals of the project in terms of safety, schedule and quality. Valmet operates in accordance with these principles and is able to supply our bioproduct mill with the best available technology (BAT). As an example, the sulfuric acid plant represents even more advanced technology. The very high environmental efficiency of the mill is achieved by combining the expertise of our staff and the technology of the mill,” says Jari-Pekka Johansson, Director of the bioproduct mill project at Metsä Fibre.

“The Kemi bioproduct mill is a trailblazing investment for which Metsä Group has chosen the most environmentally efficient and sustainable solutions. Valmet delivers all the key technology processes for the mill and offers the full benefits of our innovative full scope offering consisting of process technology, automation and services. The solutions represent leading sustainability performance with minimized emission and with the efficient utilization of side streams. As an example, sulfuric acid, which is used in mill processes, is produced using the mills odorous gases," says Bertel Karlstedt, Pulp and Energy Business Line President at Valmet.

“The mill’s advanced mill-wide automation system will be delivered with our latest technology. Valmet’s innovative web-based Valmet DNA User Interface will form the core for intelligent control of mill’s operations and maintenance. It enables efficient collaboration by letting the mill teams access relevant information securely whenever needed, regardless of their location. The delivery also includes integrated industrial internet applications to help optimize the mill’s production efficiency,” says Sami Riekkola, Automation Business Line President at Valmet.

Complete mill delivery

Valmet will deliver the full production process from wood handling to baling, designed to produce both softwood and hardwood pulp, as well as automation system for the whole mill including features from Valmet’s Industrial Internet (VII) offering. In addition, as part of the project, Valmet delivers a rebuild of the existing fiber line.

Valmet's project delivery includes engineering and supply of the main process equipment, as well as management of construction and start-up partly with an Open Book delivery model. Project’s degree of Finnish origin is estimated above 60%.

“The delivery will have an important employment impact on Valmet and its subcontractors especially in Finland. The employment impact of Valmet's project delivery is expected to be around 800 man-years, out of which about 500 man-years in Finland. Safety, close cooperation and open communication are the key success factors to ensure we reach the shared quality, schedule and cost targets,” says Risto Hokajärvi, Project Director, Pulp and Energy, Valmet.

Technical details of Valmet’s delivery

The mill will feature leading process technology and the most advanced automation systems. Valmet's delivery includes the wood handling, cooking and fiber line, pulp drying and baling, evaporation, recovery boiler, recausticizing, lime kiln, biomass dryer, gasifier, ash crystallization, mill-wide non-condensable gases (NCG) handling solution and electrostatic precipitators (ESP) for the recovery boiler and lime kiln. Valmet will also deliver the sulfuric acid plant with an extended scope of supply including construction. In addition, Valmet will deliver rebuild of the existing fiber line including new chip feeding and washing systems.

The wood handling includes log infeed system with de-icing, debarking, chipping, log washing, sand and stones removal system, chip storages, and bark and water handling system. The new wood room produces chips both to the new and to the modernized fiberline. The system is designed for low wood losses, superior and even chip quality as well as high availability and easy maintenance.

The fiberline includes the latest generation of Valmet’s Continuous Cooking technology G3 and TwinRoll wash presses to reach excellent energy efficiency, high end-product quality, high environmental performance with low effluent flows and COD (chemical oxygen demand) levels.

Pulp drying and baling line includes many advanced features to secure safe and easy operation and combined with dedicated automation and control systems makes the operations efficient needing minimum human intervention. 

The recovery line, including white liquor plant, evaporation, recovery boiler and ash crystallization, together with mill-wide NCG handling and ESPs, is tailored for high energy efficiency and minimized emissions. The recovery boiler includes modern high-power features and the energy efficiency of the mill is further improved with energy integration between evaporation and cooking processes. The ESPs are optimized for the bioproduct mill operations, to reach high availability and very low dust emissions in heavy process conditions. The limekiln is fossil-free, using product gas, which is produced from dried and gasified bark, as fuel.

The mill-wide automation delivery includes Valmet DNA control system, plant information management system, advanced process controls (APC), analyzers and online measurements, and dedicated systems for pulp dryer. The Valmet Industrial Internet features include simulators and optimizers for selected process islands as well as Valmet Performance Center connectivity.

Information about the customer Metsä Fibre

Metsä Fibre is a globally leading producer of bioproducts. Metsä Fibre is the world’s leading producer of bleached softwood pulp and a major producer of sawn timber. Currently employing approximately 1,300 people, the company’s sales in 2020 totaled EUR 2.2 billion. Metsä Fibre is part of Metsä Group.

VALMET

Corporate Communications

Valmet is the leading global developer and supplier of process technologies, automation and services for the pulp, paper and energy industries. We aim to become the global champion in serving our customers.

Valmet's strong technology offering includes pulp mills, tissue, board and paper production lines, as well as power plants for bioenergy production. Our advanced services and automation solutions improve the reliability and performance of our customers' processes and enhance the effective utilization of raw materials and energy.

Valmet's net sales in 2020 were approximately EUR 3.7 billion. Our 14,000 professionals around the world work close to our customers and are committed to moving our customers' performance forward - every day. Valmet's head office is in Espoo, Finland and its shares are listed on the Nasdaq Helsinki.