CASE MONDI SYKTYVKAR OPTIMIZING SYSTEM CREATES … · Mondi Syktyvkar mill is located in Syktykvar...

Teknosavo’s customer magazine

SYKTYVKAR KEY FACTS• Foundedin1969

• OneofthetopleadersinRussianpulpandpaperindustryandalsolargestdomesticpaperproducer.

• LocatedinSyktyvkarcityinKomi,1492kmbyrailfromthenearestport.

• Numberofemployees:approximately5000

• Annualproductioncapacityof550000tonsofpulpand830000tonsofpaper.

• Productrange:officepaper,offsetpaper,newsprint,linerboardforcorrugatedcardboard,liquidpackagingcontainerboardgradesandmarketpulp.

ABOUT MONDI: • Leadinginternationalpackagingandpapergroupwithoperationsacross30countrieswithover25,700employees.

• KeyoperationsandinterestsincentralEurope,RussiaandSouthAfrica.

“DevelopmentandservicecontractwithTeknosavoensuresthatmillwillcontinueitsprofitableproductioninthefutureaswell“

VERSATILE AND SUSTAINABLE PRODUCTION MondiSyktyvkarmillislocatedinSyktykvarinKomiRepublic,RussianFederation.Syktyvkarmillhasbeenoperatingsince1969andprovidesoffice,offsetandnewsprintpaper,containerboard,liquidpackagingcontainerboardgradesandmarketpulptothepaperindustry.

Currentlythemillisrunningthreeuncoatedfinepapermachines,onecontainerboardmachineandapulpdryer.Totalproductioncapacityisapproximately970000tonsofpaperandboardayear.Themillcomprisesofawoodyard,apulpmillwithannualcapacityof550000tons,apowerplantandacompletecomplexofwastewatertreatmentfacilities.Mondiisfollowingsustainabledevelopmentandenvironmentalprotection,as45%ofthetotalenergyproductionofthemillisbioenergy.SyktyvkarisproudofKOMICELL,aproductwhichisaFSC®certifiedmarketpulpthatisproducedwithouttheuseofelementalchlorine(ECF).

MODERNIZATION ENSURED THE PRODUCTION GROWTH In2010,MondicompletedaphasedexpansionofitsSyktyvkarfactory.Thismassivemodernisationprojectknownas‘STEP’wasimplementedwithatotalinvestmentof545M€.Themainobjectiveoftheupdateprojectwastobringthefactory’solderequipmenttothestandardofbestavailabletechnology.TheprogrammeisthelargestrefurbishmentprojectinthehistoryoftheRussianpulpandpaperindustry.Itincludesoverallexpansionandupgradeofthemill’soperations,facilitiesandequipmentaswellasreconstructionoftwopapermills,refurbishmentoffibrelines,buildingalimekilnandrecoveryboiler.Themodernisationenabledtoimprovethequalityandcompetitivenessoftheproductaswellincreasesthemill’seco-efficiency.

OPTIMIZATION SYSTEM CREATES VALUE MondiSyktyvkar’sfullyintegratedwoodsupplyopera-tionincludeswoodharvesting,roadconstruction,wood

Mondi is one of the top leaders in the Russian pulp and paper industry. It is also the largest domestic paper producer. In 2015, Teknosavo installed WoodSmartTM optimization system to Syktyvkar mill with five measurement devices on two process lines. Optimized processes led to excellent results, increasing mill’s productivity, profit and quality of the end-product.

OPTIMIZING SYSTEM CREATES BENEFITS IN SEVERAL STAGES

CASE MONDI SYKTYVKAR

transportation,reforestationandforestmanagement.Themillusesthreedifferentwoodspecies,birch,aspenandsoftwoodsuchaspineandspruce.

Fewyearsafterupgradeofhardwoodandsoftwoodfibrelinesin2015,TeknosavoinstalledtheinnovativeWoodSmartTMoptimizingsystemintwofibrelines.ItwasTeknosavo’sfirstdeliverytoRussia.Insteadofcontinuous

manualdebarkingcontrol,theWoodSmartTM,equippedwithfivepatentedonlinemeasurementsystems,isnowmaximizingthewholeprocesscapacityandqualityinwoodroom.Thesystemcalculatesthebestcontrolvariablesfordebarkingandmaintainsthewoodflowasstableaspossible.Regardlessofthewoodspecies,logsaredebarkedpreciselytotheoptimumlevelofresidualbark,whichcreatessignificantsavingsinrawmaterial.Annualamountofwooddebarkedinthesetwolinesisapproximately3,3millioncubicmeters.

FOCUS ON QUALITY DEVELOPMENT AND PRODUCTION OPTIMIZATION

AccordingtoCEOofTeknosavo,HannuHämäläinen,theWoodSmartTMsignificantlyenhancesthemill’scapacity,andcreatessavingsinrawmaterial,chemicalandenergyuse.SyktyvkarhasalreadyachievedgreatresultswithhelpofWoodSmartTMoptimizationsystemintwoyears.

“Optimizationsystemhasapositivesideeffectonthequalityoftheendproductaswell.Mondi’sproductshave

wonseveralqualitycertifications.Inordertoreachtheseachievements,therawmaterialmustbeclean.”

“WearededicatedtodeveloptheprocessfurthertogetherwithSyktyvkar.Ourdevelopmentandmaintenanceagree-mentensurescontinuousproductionimprovementinthemill.Withremotemonitoringwecanfollowhowthedebarkinglinesareperformingonadailybasisandmakeadjustmentswhenneeded.Alongsideintensivefollow-up,Teknosavomakesregularservicevisits.Comprehensiveandcontinuousserviceensuresthattheprocessesareoperatingatoptimallevel”,concludesHannuHämäläinen.Syktyvkarmillistakingtheproductiontothenextlevel.

IN THE CORE OF FLEXIBLE PROCESS AND PRODUCTION IMPROVEMENT

Manymillsarerefinedwithfirst-classtechnology.Despitethefact,forlong-termmarketsuccess,initializationofnewequipmentandtechnologiesmightnotbesufficient.Morerelevantis,howallequipmentcanbefullyutilizedandwhattypesofservicesareavailabletothem.Teknosavoenablesflexibleimprovementforprocessproductivitywithvalueclarity.Butwhatdoesitexactlymean?

INDIVIDUALLY MADE IMPROVEMENT PLAN Teknosavoalwaysprovidesacomprehensiveprestudytonewclientstoexamineallimprovementpossibilitiesin

productionprocess.Theprestudycontainsanevaluationofprofitandotherbenefits.Processoptimizationsystemusuallydenotesthatmills’annualrawmateriallossiscutby50%.Howmuchitmeansinprofit,dependsonthemill’scapacityandinitialrawmateriallosslevel.Evenmarginal

savingcanmakeadifferencewhencapacityisenhanced–savingsdonotonlyconsistofrawmaterial.Forinstance,ahighautomationrateallowslesshumanresourcesinthemill.Alsoinformationofrawmaterialincreasespossibilitiesinprocessenhancement.Valuablereportsofwoodqualityarecontinuouslyavailableandconsistofwoodlength,diameterandproductionaccordingtheweekoraday,workshiftandeventimeoftheday.

“Ifrawmaterialsavingis0,5%withanoptimizingsystem,educatedstaffandloaders,itcreatesagreatprofit.When

acustomerachievesforexample10%increaseinprocesscapacity,itisacheapinvestment.Furthermore,investinginaprocessoptimizingsolutionmaypostponesomeotherinvestmentinfuture.Profitcalculationsarealwaysversatileandintegratedcombinations.”

Teknosavo is globally known for its optimizing systems providing wood handling and pulp manufacturing companies’ versatile competitive edges. Today, the company provides an easy and comprehensive service solution to mills that wish to improve process productivity to the highest level.

CONTINOUSLY SUSTAINED AND DEVELOPED PRODUCTION Whenoptimizationsystemdevicesareinstalledtothecustomer’smill,theyareadjustedtoperformintheoperationalenvironment.Customersreceivecontinuousprocesssupportindailyorweeklybasisdependingontheneed.Teknosavoanalyzesandsetstheoptimalparameters.Withremoteaccess,itispossibletochecktheprocessstatusandforeseepossibledisruptions.Wekeeptheprocessattheoptimumlevelatalltimes.

REGULAR MAINTENANCE FOR ON-GOING PROCESSES Nobodylikesidletimesinprocess.Neitherdowe.There-fore,aregularmaintenanceisimportant.FlexibleandeasyservicesolutionsignifiesthatTeknosavo’scustomersdonothavetotakecareofthesystem’smaintenance.Teknosavohasthemostadvancedpractisesonhowtotunethemeas-urementsystemtoperformatitsbest.Ifsomethingsud-denlybreaks,24hourssparepartsdeliveryandmechanicalsupportwilltakeplace.

“Duetocomprehensiveexpertise,Teknosavogivesavaluepromisetoeachcustomer.Itisacalculated,cleareconomicalbenefitgainedwiththesystem.”

CUSTOMER DRIVEN DEVELOPMENT

When designing sensitive and complex measurement devices, including high-end technology and mechanics to variable processes, it is clear that development process takes time. During years of operation, all of Teknosavo’s devices are constantly developed to fit and perform best in the customers’ operational environment. This article unwraps the background of customer driven development in the company.

DESIGNING A COMPLEX AND ACCURATE DEVICETeknosavohasbeendevelopingadvancedtechnologysolutionsforover15years.“Ourobjectiveistonotonlyprovidethemostadvancedtechnology,butofferrealsolutionstoenhancethecustomers’processandproduct.Manyissuesmayariseinthemillsandweareheretoadviseinthesematters”,saysthedevelopmentengineerKariVirkki.HeisresponsibleofproductdevelopmentinTeknosavoandworksinateamconsistingofmechanical,electricalandsoftwareengineers.

Virkkihasalonghistorydesigningsensitivemeasuringequipment.HehasbeenworkingatTeknosavofor16years.Developmentprocessesareconstantlyongoingleadingtobetterdevices’performanceoneafteranother.

“Technologyisgoingforwardfast–soarewe.Byutilizingthelatesttechnology,camerasforinstance.Itdenotes,thatwecannotgetstuckwithcertainpartsandmechanics,thedevicewillbereformedattimes.Asthedevicesareassembliesofpartsandfunctionalitiesandtheyworkin

differentenvironments,theyareneverbulkware”,Virkkiexplains.

BETTER PERFORMANCE WITH THE HELP OF A CUSTOMER WhenthedeviceleavesTeknosavo’spremises,ithasbeencompletedanditstechnologyandmechanicstested.ItisfullyworkinginTeknosavos’circumstancesbuteventualtestingandrefiningwillbedoneinthecustomer’sfacilities.“Everymillandproductionprocessisslightlydifferent

WOODSMARTTM

DEBARKING OPTIMIZATION

Teknosavo in numbers

Teknosavo’s service explained

Optimization creates value

CASE 1Wood species SpruceWood loss without optimized debarking

CASE 2Wood species Spruce

Of the world’s biggest pulp producersuse Teknosavo’s systems.

Teknosavo’s systems have been delivered worldwide.

Number of countries Teknosavo’s systems have been delivered to.

CASE 3Wood species Birch

5,80%

2,60%

0,70 - 1,20%

6,29%

2,94%

Teknosavo’s services range from gate to digester. Our optimization service is based on continuous development which creates savings in raw material and energy.

Our optimization services decrease our clients’ raw material loss on an average annual level 1-4%.

For a single debarking line, this can mean up to 1 million euros in energy and raw material.

Wood loss with optimized debarking

3,40%

The product development is always teamwork in Teknosavo.

dependingonthepremises,rawmaterialandtechnologyused.Forexample,whenwewereinstallingChipSmart,thereal-timechipqualitymeasurementdeviceforourcustomer,wenoticedthatlongwoodsticksinrawmaterialarecausingseveralprocessinterceptions.Thiswasnotexpectedandwehadtosolvethesechallengesafterwardsbymechanics.Itisanormaladjustingprocedureandcustomerhasimportanceindevelopmentprocess.Theyhelpustomakeevenbetterdevices”,Virkkiconcludes.

AllTeknosavoequipmentwillbetestedandrefinedafterinitializationwithhelpofthecustomer.Itisfairtosay,thattheproductsaredevelopedtofitcustomer’sneeds.

ABOUT CHIPSMART:Chipsmartisanopticalmeasurementdevicethatisdesignedforreal-timemeasurementofchipquality.Theresultshowschipqualitydatasuchaschipsurfacebrightness,theextentofbarkandotherimpuritiesinthechipflow,changesofchipsurfacemoisture,chipthickness,changesofchipsizeclassificationandmaterialvolumeflowonthechipconveyor.

Themeasurementdatacanbeusedfordebarkingcontrolmonitoringtheconditionofthechipperbladesorpurchasedwoodchiptoavoidunnecessarydisruptionslaterinthechiphandlingprocess.ThedatacanbeconnectedtotheWoodSmart®processoptimizationsystem,inthewoodroomautomaticmaincontrolsystem,orshowninthecontrolroomonaseparatedisplay.Thesystemconsistsachiphandlingmechanicsandopticsunit,adisplayscreen,andaPCunithousing,theanalysisandmaintenancesoftware.

Hanna Matilainen is dedicated to enhance customer’s processes.

WE KEEP UP DEVICES OPTIMAL PERFORMANCE AT ALL TIMES

Company’sdedicatedandtalentedworkforceensuresthatthemostcomprehensiveserviceisalwaysavailable.HannaMatilainenisresponsibleofoperativemanagementinTeknosavo.Indailybasissheisworkingwithavarietyoftasksfromclientregistermanagementtodevicesinitialization.AccordingtoMatilainen,allinthecompanyhavehands-onwhenitcomestoservingthecustomer-dirtyormalfunctioningdeviceisshowingfalseresultsleadsfastqualitydeclineandprofitloss.Hannahasvaluableknowledgeincustomers’processdevelopmentandknowshowproblemsituationscanbeforeseenandavoided.

SERVICE PROCESS IS ALWAYS CUSTOMIZED ACCORDING THE CUSTOMER’S NEEDS

“Onlyregularlymaintainedmeasurementdevicesassureoptimalproduction.Unfortunately,sometimesthiscanbeaccidentallyforgotteninthemills.InTeknosavowedefinitelyunderstandallissuesthatwoodprocessingmayinvolve.Therefore,weprovidelargescalemaintenanceservicesforourcustomers.Startingfromthebasicmaintenancevisits,wealsoofferphoneandremotesupport,spareparts,repairservicesandstatusmapping.Becauseeverymillvariesfromeachother,alldevicesandserviceoperationsarecustomizedaccordingtocustomer´sneeds”,saysMatilainen.“Thebasicmaintenancemeansaccuratecheckingprocessofequipmenttoensuretheoptimalperformance.Theprocessitselfisquitesimilarineverymill;firstwechecktheconditionofmeasurementdeviceunitandcleancriticalcomponents.Thesearefollowedbycalibrationandtestingwhichconfirmsthatserviceactionshavesucceeded.

Allourdevicesinvolveacomputertoruntheprograms.Aftercleaningandcalibration,wecontinuecheckingontheelectricityunit.Itisimportantthattheaircondition

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filtersarecleanenoughtoavoidoverheating.Atthesame,wecheckthatthecomputerworksproperly.Mainfocusisobservingthatnothingunexpectedisshownwhichmightjeopardizesafetyordevicesfunctionality.Ifwenoticeanyproblemsorneedstoreplacedamagedparts,wecanactimmediately.Incasetheprocesslinewillberunimmediatelyaftermaintenance,wewillalsochecktheimageanalysis.Forexample,whenthewoodqualitychangesradically,itwillaffectondetection.Usuallythereisnoneedtomakechangesbutwhenneeded,wewilladjusttheparameters.Thebasicmaintenanceinvolvesthewholesystem.”

HOW OFTEN BASIC MAINTENANCE SHOULD BE DONE?“Recommendationisminimumonceinamonth,butfordemandingconditionsbasicmaintenanceisadvisableineverytwoweeks.Neglectingregularmaintenancewillquicklyhaveanaffectbecauseforexampleadirtybottomglasswillleadtofalseresults.Theresultmightbecomedistortedalreadyinafourweekperiod.Evenwithautomatedsystems,thereisaneedforregularchecksandensurethesufficientamountofcleaningdetergent.”

WHAT IS THE ADVANTAGE THAT THE SERVICE WILL BE DONE BY TEKNOSAVO?“Wewillalwaysgiveamaintenanceguideforourdevices.Everymillcanmakethebasicmaintenancethemselvesoroutsourcetheservice.TherearestillamultitudeofadvantageswhyshouldTeknosavotakecareofthemaintenance.Forexample,wecancheckthecustomers’diagnostics,logfilesandanalysedata.Previousdisturbancesincameraconnectioncanbeexaminedandwecansolveproblemsalreadyduringthevisit.Withpropermaintenance,allbiggerissuescanbeavoided.Thiskeepsthequalitysteady,shortensdowntimesandsavesresources.”

2017

SKILLED EXPERTISEAT YOUR SERVICEAdvanced technical solutions, such as optical measurement devices are sensitive for external disturbances. To keep up their optimum functionality at all times, a regular maintenance is the key. Teknosavo provides reliably working measurement systems with comprehensive device maintenance and process development.

Ouragreementcustomerscanleavethemaintenanceandthesupportrequestsrelatedtotheapplications

everydayoftheweek.

Wemonitorourcontractcustomers’diagnosticandmeasurementdata.

Thebasicmaintenancemeansaccuratecheckingprocessofequipmenttoensurethe

optimalperformance.

Maintenanceagreementiseasywaytoensurefulladvantageofthesystem.

Teknosavowillalwayschecktheanalysisandadjustparameterswhenneeded.

EXPOCORMA, CHILE

8TH - 10TH NOVEMBER 2017EXPOCORMAisoneofthemostimportanteventsintheforestryindustryinLatinAmerica.Theinternationaltradefairgathersover350ofthetopcompaniesinareasofforestry,pulpandpaper.Teknosavowillbeshowcasingtheoptimizationsystemsandon-linemeasurementsystemsforwoodprocessing.See you there!