Case Study LIFE2IMPROVE - Performance Optimization

What can operators in the production of paper and board do if a starch processing plant is running at a much lower capacity than originally planned after several years of operation? 

Find out how to prevent costly production stops as well as to avoid concentration fluctuations in the slurry preparation or temperature fluctuations with this GAW case study:

LIFE 2 IMPROVE – PERFORMANCE OPTIMIZATION by the GAW Performance Coach

Optimization of Starch Preparation and Working Station to Filmpress

📝 Task & definition of the problem:

An enzymatic starch processing plant at a customer in America was running at a much lower capacity than originally planned after four years of operation. Amongst other things, steam hammering and vibrations in the system caused production stops every 120 minutes. Concentration fluctuations in the slurry preparation as well as temperature fluctuations throughout the system were also observed. At the working station, overused rejection of the filter systems generated a large amount of wastewater and product loss. The operating staff was new and insufficiently trained.

⚡ Consequences & Impact:

• The piping system and the cooker were already showing wear and tear
• High levels of wastewater and product losses at starch preparation and working stations
• High starch and energy consumption due to fluctuations in concentration
• Paper quality problems (strength)
• Various operating errors

💡 Solution statement & approach:

All parts of the system were observed and analyzed by a GAW Performance Coach during operation, using trend recordings. Furthermore, intensive conversations with the operating staff followed with discussions about the operation mode as well as the best possible operation of the entire system.

💪 Measures & actions:

• Maintenance and cleaning works were carried out.
• The operating personnel received in-depth training.
• By optimizing the controllers/levers, concentration fluctuations with a maximum of ± <0.5% and temperature fluctuations of ± <1.0°C were ensured (which were <3% and <5°C before optimization).
• The flushing times were optimized.
• A general optimization of the plant capacity was executed.
• Reduction of the amount of wastewater by optimizing the filter systems.

✔ Customer benefits & added value (figures, data, facts):

Thanks to the optimization, the starch preparation and the working station now operate synchronously with the production consumption of the paper machine. The amount of wastewater and starch losses was significantly minimized. Due to the training and optimization, the customer achieved increased availability of the system and thereby also reduced the production costs. Furthermore, the lifetime and operational life of the system was significantly extended.

Total SAVINGS: EUR 150,000 per year

You can find the link to the PDF Version of the Case Study including details and contact data here.

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September 2024