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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!