June 2016 © Valmet 2
Shared Journey Forward Valmet’s way to serve
Over the years we have been constantly
developing our services to improve the reliability
and performance of your processes.
After adding automation to our offering in 2015,
the natural next step was to start unifying our
services offering and the way we serve you.
Our services offering is now easy to understand
and choose from.
To give you the best service experience we
have defined our core commitments to you.
The landscape of our shared journey
Industry challenges
Volatile raw
material and
energy costs
Global
industrial
competition
Rising labor
costs and skills
shortages
Increasing
environmental and
safety requirements
Constant
changes in
market conditions
Global megatrends
How to keep
equipment and
processes
running reliably
How to optimize the
performance of industrial
processes to get the
most out of the least
How to ensure
process
competitiveness with
latest innovations
How to get
the right
expertise
when needed
Digitalization
How to best utilize
the opportunities
of digitalization
and Industrial
Internet
June 2016 © Valmet 3
Committed to moving your performance forward
Safety
comes first
Close to you
Solutions to
your needs
People you
can trust
Our core commitments
Performance
• Production consumables
• Process support and optimization
Reliability
• Spare parts and components
• Maintenance and shutdown management
• Outsourcing services
• Process and automation upgrades
• Automation projects
• Industrial Internet and remote solutions
New Technology
Services offering
Shared Journey
ForwardValmet’s way to serve
June 2016 © Valmet 5
Safety comes first
Safety is never compromised in our daily
operations.
Our LTI* statistics show that we take safety
seriously.
We are committed to supporting you in
reaching your safety targets, like:
– Accident and incident free mills and plants
– Employee well-being and productivity.
– No short or long term losses due to low safety
– Better productivity through safe and effective
procedures
– Maintaining and improving brand and
sustainability image
* LTI = Lost Time Incidents
June 2016 © Valmet 7
Close to you
We work close to our customers, even being on
site daily.
Our experts are available also remotely with the
help of Industrial Internet technologies.
We have continuous cooperation with customers.
Being close means sharing best practices.
You can also reach us through 24/7 on call
service.
Being close to you is the key for us to
understand your specific needs and to develop
right solutions just for you.
professionals
12,000locations
130service centers
100+countries
33services agreements
– many of them with remote
connections to customers
1200
April, 2016 © Valmet 8
Online connections
with customers
480
Our solutions are based on the unique
combination of process technologies,
services and automation – to your benefit.
We develop the solutions in close
cooperation with you to meet your needs in:
– Safety and sustainability
– Production efficiency
– Energy efficiency
– Raw material efficiency
– Maintenance efficiency
– Cost efficiency
– Optimized quality
Customer
Solutions to your needs
June 2016 © Valmet 9
We want to earn your trust by
– keeping our promises
– not letting our customers down
– open and prompt communication
– sharing common goals.
We have a unified way to serve to
ensure repeated high performance
through
– working safely
– listening to you
– being responsive and committed
– delivering what has been agreed.
People you can trust
June 2016 © Valmet 10
Services offeringReliability Performance New Technology
Spare parts and
components
Maintenance and
shutdown
management
Outsourcing
services
Production
consumables
Process support
and optimization
Process and
automation
upgrades
Industrial Internet
and remote
solutions
Automation
projects
• Spare parts
• Replacement
components
• Spare part packages
• Spare parts
shutdown planning
• Inventory
management
• Exchange unit
service
• Inventory
optimization
• eServices
• ePartsBook
• Parts installation
• Technical support
• Preventive
maintenance
• Shutdown
management
• Corrective
maintenance
• Modernizations
• Automation security
• Condition monitoring
and analysis
• Maintenance audit
• Preventive
maintenance
planning
• Shutdown planning
• Shutdown
maintenance
• Logistic services
• Health and Safety
advisor
• Maintenance
outsourcing
• Workshop
outsourcing
• Mill inventory
management
• Process parts
• Paper machine
clothing
• Filtration fabrics
• Roll covers
• Product technology
support
• Process technology
support
• Product tracking
• Cost predictability
• Inventory
management
• eServices
• Advanced process
controls
• Automation
applications study
• Process technology
support
• Process studies
• Process optimization
• Competence
development
• Performance
agreement
• Health and safety
upgrades
• Energy efficiency
upgrades
• Quality upgrades
• Capacity upgrades
• Efficiency upgrades
• Raw material and
fuel improvements
• Automation
upgrades
• Environmental
system upgrades
• Process
benchmarking
service
• Process piloting
service
• Consultancy
• Greenfield projects
• Automation
renewals
• Automation
extensions
• Engineering
services
• Remote support
• Remote optimization
• Centralized
operations
• Condition study
• Maintenance
management
system
• On-site supervision
• Workshop
maintenance
• Technology
roadmapping
service
• Remote and
analytics services
June 2016 © Valmet 12
Spare parts and components
Spare parts
Service Description: High quality spare parts to restore
normal equipment or system operation. Original parts for
Valmet machinery and legacy brands, and Valmet approved
replacement parts.
Results: Standard, pre-determined schedule or express
delivery cost-effectively with added services when agreed.
Replacement components
Service Description: High quality components such as
replacement rolls and dewatering elements to restore or
improve equipment or system operation.
Results: Improved component functionalities. Standard or
express delivery cost-effectively with added services when
agreed.
Spare parts packages
Service Description: A selection of spare parts purchased
with the machine delivery (rebuild or a new installation);
Package size can be defined according to the cost of
machinery and the chosen risk level.
Results: Ensure the successful start-up of machinery,
system or rebuild: Avoid and minimize downtime and
production losses; Ensure safety devices’ functionality at all
times; Ensure successful testing and startup phase of new
machinery; Keep up high quality long term production
June 2016 © Valmet 15
Reliability
Spare parts shutdown planning
Service Description: A proactive shutdown planning service
with tight co-operation jointly with the customer: parts and
personnel needed for shut-down with detailed scheduling.
Valmet validates customer inventory and tracks deliveries.
Results: Ensured parts availability at right time. Increases
uptime as correct parts and expertise available for the shut-
down. Reduces customer planning and supply chain work
load; reduces spare parts freight costs and stock value.
Spare parts and components
Inventory management
Service Description: Valmet plans and manages parts
inventory either at customer site or establishes buffer stock
at Valmet logistics center to ensure parts availability. Parts
can be owned by customer or by Valmet as agreed. Valmet’s
logistics network is the backbone to the effective supply.
Results: Parts available for production or for maintenance
works when needed at agreed risk level. Increases uptime,
ensures critical parts availability. Reduces stock value for the
selected scope.
Inventory optimization
Service Description: Valmet analyzes existing inventory
against the current installed base and maintenance plans to
identify correct parts. In addition criticality analysis is used to
propose optimal spare parts management.
Results: Increases uptime, ensures critical parts availability.
Reduces stock value. Up-to-date knowledge about current
spares against the installed base. Support for planning
optimal spares management.
Exchange unit service
Service Description: Valmet keeps available, overhauls and
rotates exchange units or reconditions parts.
Results: Exchange units available for fast replacement at
minimized unit and related net working capital costs.
June 2016 © Valmet 16
Reliability
Parts installation
Service Description: Valmet installs the spares parts
according to timetable jointly agreed with the customer.
Results: Parts installed correctly and timely.
Spare parts and components
eServices
Service Description: An online store for parts management
and purchasing including access to extensive product
information, parts availability, lead times and pricing. A
channel to reach Valmet to inquire technical support and
troubleshooting.
Results: Fast and easy identification and purchasing of spare
and wear parts, visibility to quote and order history and on-line
tracking of orders. Quick access to technical and other
documentation related to parts and fast way to reach Valmet
customer service.
ePartsBook
June 2016 © Valmet 17
Reliability
Service Description: Interactive up-to-date parts catalogue
tailored to customers’ installed base with drill-down assembly
tree structure, drawings, bills of materials, spare parts
information and maintenance and operations instructions. Is
linked to eServices at part level.
Results: Find the correct parts faster: faster part ordering
with fewer errors; increased equipment and production up-
time; lower repair and spare part inventories; quicker supply
chain response time. Additional benefits through the link to
eServices.
Maintenance & shutdown management
Corrective maintenance
Service Description: Repair of broken process equipment,
system items or components either on-site or at Valmet
facility. Failure investigation and root cause analysis if
required.
Results: Get broken item back into operation. Root cause
analysis identifies the issue, the root cause and the
preventive action(s) required.
Technical support
Service Description: Technical support via phone and/or
remote connection with service available as 24/7 or 8/5.
Guaranteed call back and on-site response times for
emergency situations.
Results: Prompt resolution and expert support to minimize
any disruption to production process. Dependable expertise
and resources backed by a greater global network of
experts.
Reliability
Condition study
Service Description: Process equipment, systems or
devices are inspected to check their condition. Status and
recommendations are reported to customer.
Results: Up-to-date information about the condition of your
installed base. Results of the study contribute to fast
troubleshooting, maintenance planning, and plant
development.
Automation Security
Service Description: Continuous follow-up with new
information on current security risks. Testing of selected
security upgrades in the Valmet DNA system test
environment and delivery to customer’s system.
Results: Minimized risk of malware and cyber attacks.
Ensured reliability of Valmet DNA system.
June 2016 © Valmet 18
Maintenance & shutdown management
Reliability
Preventive maintenance
Service Description: Valmet performs regular planned
maintenance tasks for equipment and systems.
Results: Long problem free operational life time
Preventive maintenance planning
Service Description: Planning of preventive and predictive
maintenance actions either for a selected process or system
or full machine line. Plans are delivered in a format that can be
implemented in mill’s CMMS system.
Results: Optimized maintenance plans reduce unplanned
shutdowns, increase maintenance cost efficiency, and
upkeep asset value.
Condition monitoring and analysis
Service Description: Continuous monitoring and analysis of
machine and automation system health. Diagnostics based
detection of emerging faults and input for proactive
maintenance planning and execution.
Results: Resolution of problems before they have a critical
business impact. Helps reduce costs by streamlining
activities.
Maintenance management system
Service Description: Valmet Maintenance Management
System (CMMS) is configured with best practise work flow
for maintenance. Asset register is included based on capital
project data. Valmet CMMS is based on Infor CMMS system.
Results: Pre-configured Maintenance Management System
including work flows and project data.
June 2016 © Valmet 19
Maintenance & shutdown management
Shutdown planning
Service Description: Shutdown planning including work
scopes, spares, resources, accessories and time schedules.
Maintenance execution as an option. Typically done for a
selected process.
Results: Clear maintenance instructions to execute planned
maintenance actions. Turn key delivery as on option
Reliability
Shutdown maintenance
Service Description: Execution of the planned maintenance
activities with material, tools and personnel at the shutdown.
Scope varies from equipment special maintenance to plant
wide overhauls.
Results: All services and materials defined and purchased
in advance. Efficient execution to time and budget.
Shutdown management
Service Description: Valmet solution for providing planning,
management, shutdown maintenance activities, coordination
and logistics of subcontractors from stopping of production
until your process is up and running in full production again.
Results: Shutdown on time and within budget.
Uncompromised safety. Reports provides basis for planning
of next shutdown.
On-site supervision
Service Description: Valmet specialist works as an advisor
or supervisor for specified on-site service action.
Results: Access to OEM technology know-how during the
on-site service action.
June 2016 © Valmet 20
Workshop maintenance
Service Description: Maintain current process part or
equipment at Valmet facility.
Results: Improved well performing equipment or process
part. Lower the risk of process failures
Maintenance & shutdown management
Logistic services
Service Description: Valmet to handle transportations and
other logistic services needed in connection with
maintenance at Valmet facility.
Results: Easy Door to Door service. Cost efficient and
reliable arrangement to ensure on-time delivery of
components.
21
Reliability
21
Modernizations
Service Description: Improve current process part or
equipment with new features either on-site or at Valmet
facility.
Results: Improved equipment performance.
June 2016 © Valmet 21
Maintenance & shutdown management
June 2016 © Valmet 22
Reliability
Health and Safety advisor
Service Description: Valmet HSE expert is present on-site
during HSE inspections to provide Valmet insight to the issue.
Results: Supplier’s professional support reduces the risk of
serious hazards due to malfunctioning safety systems or
working practices.
Maintenance audit
Service Description: Audit of a maintenance workshop or
all maintenance operations. Operational exellence, cost
performance, and condition of maintenance equipment are
analyzed and benchmarked.
Results: A report describing the current operational stage
and a path to go for improved maintenance efficiency.
Outsourcing services
Maintenance outsourcing
Service Description: Valmet takes responsibility of all
maintenance operations and management on-site. For new
mills/plants Valmet also establishes maintenance
organization and processes as a turn key service.
Results: Turn key solution for first rate maintenance that
reduces unplanned shutdowns, lowers maintenance costs
and maintains the value of assets. Valmet’s know-how
available 24/7.
Workshop outsourcing
Service Description: Valmet takes responsibility of
customer’s maintenance workshop operations and
management.
Results: Professional workshop services minimize
equipment failures and service costs. Valmet can optimize
the use of workshop by bringing in equipment from other
mills if capacity allows.
Mill inventory management
Service Description: Valmet takes responsibility of
customer’s materials management for spare parts and
production consumables. For new mills/plants Valmet also
establishes materials management as a turn key service.
Results: Complete solution for optimized materials
management. Reduced yearly spend on materials.
Reduced Net Working Capital. Improved parts availability.
June 2016 © Valmet 23
Reliability
Production consumables
Process parts
Results: Optimization toward production cost, quality,
capacity and availability. Maximized production, lowest life
cycle costs and reliable product performance. Opportunity for
energy and raw material savings and quality improvements.
Paper machine clothing
Service Description: High quality, tailored products for all
paper, board, tissue and pulp grades.
Filtration fabrics
Service Description: High quality fabrics for all filtration
needs in pulp and paper manufacturing as well as in energy
production.
Roll covers
Service Description: High quality, tailored covers for all
applications in paper, board, tissue and pulp manufacturing.
Products ranging from economy to durability and
performance.
Results: Optimization toward production cost, quality,
capacity and availability. Maximized production, lowest life
cycle costs and reliable product performance. Opportunity for
energy savings and quality improvement.
Results: Optimization toward production cost, quality,
capacity and availability. Maximized production, lowest life
cycle costs and reliable product performance. Opportunity for
energy savings and quality improvement.
Results: Optimization toward production cost, quality,
capacity and availability. Maximized production, lowest life
cycle costs and reliable product performance. Opportunity for
energy savings and quality improvement.
June 2016 © Valmet 25
Performance
Service Description: Full range of high quality process parts
– such as refiner segments, screen baskets, various blades
and sizer consumables - tailored to their application. Products
ranging from economy to durability and performance. Valmet
experts develop the right solution/product to meet customer’s
targets: on site in cooperation with the customer.
Production consumables
Product technology support
Service Description: Valmet expert provides product
related technology support such as measurements, trouble
shooting, adjustments, and operator training.
Results: Optimized product performance.
Process technology support
Service Description: A Valmet expert performs a process
performance or operation related task requested by
customer. The tasks can be related to, trouble shooting,
process tuning or operational support.
Results: Operational and performance related issues
solved.
Performance
Inventory management
Service Description: Valmet plans and manages parts
inventory either at customer site or establishes buffer stock
at Valmet logistics center to ensure parts availability. Parts
can be owned by customer or by Valmet as agreed. Valmet’s
logistics network is the backbone to the effective supply.
Results: Parts available for production or maintenance
works when needed at agreed risk level. Increases uptime,
ensures critical parts availability. Reduces stock value for the
selected scope.
June 2016 © Valmet 26
Cost predictability
Service Description: Commercial model based on
predetermined fixed monthly fees or production based fees.
Results: Full cost predictability by fixed monthly fees or
production based fees.
Production consumables
June 2016 © Valmet 27
Performance
Product tracking
Service Description: Valmet provides product tracking for
inventory management.
Results: Real time inventory information. Secured product
availability. Running time information.
Remote and analytics services
Service Description: Trouble shooting, production
optimization, maintenance and start-up support. Equipment
condition monitoring and process performance optimization.
Results: Information available for production optimization.
Visibility of equipment condition. Fast reaction. Proactive
trouble shooting.
eServices
Service Description: An online store for parts management
and purchasing including access to extensive product
information, parts availability, lead times and pricing. A
channel to reach Valmet to inquire technical support and
troubleshooting.
Results: Fast and easy identification and purchasing of spare
and wear parts, visibility to quote and order history and on-line
tracking of orders. Quick access to technical and other
documentation related to parts and fast way to reach Valmet
customer service.
Process support and optimization
Process studies
Service Description: Testing and analysis of performance
improvement potential. Customized proposal for solutions to
improve process performance.
Results: Definition of the required solution to meet the
customer objective. Precise information of improvement
potential and payback calculations to support investment
decisions.
Process optimization
Service Description: Performance evaluation and process
optimization by our experts based on available tools, such as
advanced controls, measurements and analyzers. Can
include continuous monitoring and tuning of the process.
Results: Optimized process performance, e.g. reduced
variability, reduced costs, increased production, or
optimized environmental performance.
Process technology support
Service Description: A Valmet expert performs a process
performance or operation related task requested by
customer. The tasks can be related to, trouble shooting,
process tuning or operational support.
Results: Operational and performance related issues
solved.
Performance
Automation applications study
Service Description: Applications are checked against the
process changes, user experience or latest environmental
legislation. Definition of development needs and
improvement potential.
Results: Precise awareness of the current status of
applications and their usage. Proposal for long-term and
short-term improvements. Ensures high quality information
and maximized usability of the applications.
June 2016 © Valmet 28
Performance agreement
Service Description: Performance agreement is a business
solution combining process, operational and maintenance
services in a long-term agreement targeting agreed KPI´s. A
committed Valmet team working alongside with customer’s
team on a systematic and continuous basis.
Results: A systematic approach to improve and optimize
plant/mill performance to achieve customer´s goals related
e.g. availability, productivity, energy and cost targets.
Competence development
Service Description: Customized and standard courses,
on-site or off-site. Training is supported by advanced tools,
such as simulators and WebAcademy online training portal.
Services include also skills assessment, identification of
compentence gaps, and course curriculum planning.
Results: Confident and skilled personnel ensure safe, stable
and efficient start-up and operation with minimized
environmental risks. Increased cross-functional awareness
leads to higher availability across the plant. Training scope
corresponds to individual needs, based on company targets,
to ensure maximum ROI.
June 2016 © Valmet 29
Performance
Advanced process controls
Service Description: Advanced control application
packages for pulp, paper and power processes for process
optimization.
Results: Step change in performance for reduced variability
reduced costs, increased production or optimized
environmental performance.
Process support and optimization
New technologyEnsuring process competitiveness with the help of latest innovations and Industrial Internet
Process and automation upgrades
Health and safety upgrades
Service Description: Complete delivery of machine and
automation updates (e.g. motion sensors, safety lockings) and
mechanical installations (e.g. fences / shields) with training
and start-up support.
Results: Improved safety and working environment.
Lowered risk for health and safety accidents motivates
people and enables improved health and safety KPIs (Lost
Time Incidents).
Energy efficiency upgrades
Service Description: Common target setting, energy
benchmark for baseline analysis. Complete delivery of key
components, automation updates, installations with start-up
and process support.
Results: Reduced energy consumption in manufacturing
process. Direct savings in electricity (drives, pumps) or
steam usage. Guaranteed and documented energy saving
improvement results.
Quality upgrades
Service Description: Common target setting, quality
benchmark and laboratory analyses for baseline analysis.
Complete delivery of key components, automation updates,
installations with start-up and process support.
Results: Improved and consistent end product quality.
Quality Upgrades can have impact on fiber orientation,
formation, curl, bulk, smoothness, gloss and other quality
factors. Guaranteed and documented quality improvement
results.
June 2016 © Valmet 31
New technology
Capacity upgrades
Service Description: Common target setting, capacity
benchmark for baseline analysis. Complete delivery of key
components, automation updates, installations with start-up
and process support.
Results: Improved production capacity due to improved
production process or removal of bottlenecks. Guaranteed
and documented capacity improvement results.
Process and automation upgrades
Efficiency upgrades
Service Description: Common target setting, production
efficiency benchmark for baseline analysis. Complete
delivery of key components, automation updates,
installations with start-up and process support.
Results: Improved machine and process efficiency. Results
will be gained by improved production line availability,
minimized production breaks, and less material losses.
Guaranteed and documented efficiency improvement results.
Raw materials and fuel improvements
Service Description: Common target setting, raw materials
and fuel benchmark for baseline analysis. Complete delivery
of key components, machine and automation updates,
installations with start-up and process support.
Results: Direct savings in raw materials and fuel cost. New
technology enables the use of lower grade / economical
materials and fuels. Guaranteed and documented raw
material and fuel saving results.
Automation upgrades
Service Description: Automation system upgrades in
accordance with technology roadmapping. Flexible scaling
from small partial upgrades to large one shot upgrade of the
whole system.
Results: Optimized system lifecycle cost. Improved process
and system efficiency and reliability. Improved usability with
user interface updates and new software features.
June 2016 © Valmet 32
New technology
Environmental system upgrades
Service Description: High quality environmental equipment,
parts and systems tailored to their application for better
environmental performance.
Results: Reduced environmental impact. Compliance with
new environmental standards and requirements.
Process benchmarking service
Service Description: Benchmark study includes data
collection from the customer and benchmark analysis to
industry peers. Benchmark service focus is on process main
KPIs or details in energy or raw materials usage
Results: Understanding of the current level of the process
baseline level compared to industry peers. Benchmark study
also give directions to the process improvements.
Process piloting service
Service Description: Process piloting can be done for the
the whole process (paper, board, tissue, power) or specific
sub processes. Pilot plans are done together with customers
and can executed in Valmet pilot plants or in customer’s site
Results: Accurate information for upcoming process
changes and lower risks for the investments. As an example
raw materials base, fuel types and new technology concepts
can be tested before implementing them in real production.
Technology roadmapping service
Service Description: Building a proactive plan on how to
upgrade the automation system or process equipment the
best possible way in the coming years.
Results: Optimized and predictable total cost of ownership.
Accurate budgeting.
June 2016 © Valmet 33
Process and automation upgrades
New technology
Greenfield projects
Service Description: Delivery of a new automation system
of the latest technology to a completely new plant, including
project management, engineering, testing, start-up and
documentation.
Results: On-time and on-budget delivery to meet customer
business goals with the best possible new technology.
Automation renewals
Service Description: Renewal of an existing old automation
system with a completely new system of the latest
technology.
Results: On-time and on-budget delivery to meet customer
business goals with the best possible new technology.
Consultancy
Service Description: Expert clarification and guidance to
find the best possible technology solution for each customer-
to reach customer business goals.
Results: Ensures business goals are reached. Better risk
control and secured payback time.
June 2016 © Valmet 34
Automation projects
New technology
Engineering services
Service Description: Making modifications or additions to
automation applications due to process technology updates,
operation mode changes or user experiences.
Results: Up-to-date applications to ensure business
continuity and to meet production goals.
Automation extensions
Service Description: Enlargement of an existing automation
system with a new subsystem, automation nodes or
applications. The extension may be either latest technology
or some older appropriate technology.
Results: On-time and on-budget delivery to meet customer
business goals with the best possible technology. Ensured
capacity of the system.
June 2016 © Valmet 35
Automation projects
New technology
Remote optimization
Service Description: Advanced Analytics and Big Data
tools are utilized to support remote process monitoring, data
analysis and optimization.
Results: Improved quality and cost efficiency through higher
energy efficiency, reduced raw material consumption and a
reduced downtime.
Centralized operations
Service Description: Introduction of remote, mobile and
centralized solutions for process supervision, allowing
mobile and centralized plant operation.
Results: Improved cost efficiency. Mobile visibility of plant
condition.
Remote support
Service Description: Expert support trough remote
connection to assist with troubleshooting, fault tracing and
corrections.
Results: Reduced downtime and increased availability.
June 2016 © Valmet 36
Industrial Internet
New technology
Customer’s process
Today, customers are extensively utilizing our Industrial Internet capabilities
Online
connections
Performance
agreements with
remote
connections
Co-creation of
advanced
analytics with
customers
Valmet-supplied
lines with Valmet
DCS
48035070 000
80Advanced
process control
installations
320740 Ongoing
Valmet’s remote center
Valmet’s competence
network
350 Condition
Monitoring (CM)
references with
over 70 000 I/O
tags
June 2016 © Valmet 37
New technology
Results:
The agreement allows the mill to plan better and reduce maintenance shutdown surprises.
Considerable inventory savings are gained as the mill-owned stock of spare and replacements parts is reduced and provided from Valmet’s nearby warehouse.
Secured production line availability
© Valmet
Sappi Kirkniemi mill, Finland
Background• Sappi’s Kirkniemi mill extended its cooperation to a frame
agreement covering various services and spare parts for all of
their three papermaking lines.
• Especially the tail threading equipment maintenance needed
the expertise skills that were not sufficiently available in-house.
Target• The primary goal of the project was to improve the operational
reliability and safety of the tail threading process. Also
opportunities for wear part inventory savings needed to be
recognized.
Our Solution • A service agreement covering audit and maintenance plan on
all three machines, emergency service with short response
times and availability of spare parts.
• Also the availability of the automated tail threading equipment
was guaranteed.
Reliability
Results:
The paper making surface is excellent
The coating has greatly extended the life of the dryer and the continuous run time of the machine
No chatter marks
“Today, we have almost no Yankee wear. Both
machines have been running trouble-free for
more than 12 years without regrinding. We are
very satisfied with the result.”
Josef Berger, Factory Manager TOIPA,
SCA Hygiene Products GMBH
(2012)
Thermal spraying eliminated chatter marks
© Valmet | Author / Title40
SCA Ortmann, Austria
Background• PM4 is the widest tissue machine in Europe with a sheet width
at the reel of 6,92 meters. Consequently it also has the largest
Yankee dryer.
Challenge• Because of chatter marks, the Yankee dryer of PM4 requested
regrinding - twice a year. The situation became untenable and
requested a permanent solution.
Our Solution • To thermal spray the Yankee dryer using Infinikote® thermal
coating from Valmet.
Reliability
Results:
Digester 1 (93%) and digester 2 (34%) improved hitrate of kappa to target range
Savings of USD 650,000 in digester 1 and USD 900,000 in digester 2 per year
Variability reduction enabled yield increase
June 12, 2016 © Valmet41
Celulose Nipo-Brasileira AB Cenibra, Brazil
Background• Cenibra is one the largest pulp producers in Brazil and is also a
pioneer in eucalyptus pulp production
• Ipatinga Mill’s two lines produce 1.2 Mt per year of ECF
bleached eucalyptus pulp
Challenge• Extreme variability in chip quality causing process disturbances
• Need to stabilize pulp quality by reducing disturbances and
kappa number variation
• Need to improve pulp yield and lower cost per ton once
processes stabilized
Our Solution • Continuous Cooking Optimization
• Valmet Kappa and Alkali Analyzers
• Projects and Engineering
Valmet implemented the Continuous Cooking Optimization
Solution to stabilize the cooking process.
“We had an average kappa of 15, and our
objective was to reach 17. A higher value
means higher wood utilization. Working
together we got very good results, which
were much better than expected and which
have been maintained.”
Hamilton Brandão, Recovery and Utilities
Coordinator
Performance
Results:
Energy consumption was improved by 5%, saving 5 GWh of energy annually
Payback in just a couple of months
Pulp quality is being kept on an optimal level
More than 5 GWh in annual energy savings
© Valmet
Estonian Cell, Estonia
Background• In 2012, electricity prices and distribution costs in Estonia rose
to a very high level
• Estonian Cell, a high-yield mechanical pulp producer – and
Estonia’s largest consumer of energy – faced a pressing need
for additional energy savings in their primary refiner
Challenge• To optimize the refining process in order to achieve energy
savings while maintaining or even improving pulp quality level
Our Solution• The mill signed a ProGap refiner segment optimization
agreement that combines accurate disc-gap control with
Valmet energy-saving segments
• The agreement also included a new AGS (Adjustable Gap
Sensor) to accurately measure the disc gap
“We are satisfied with the results. Our
primary refiner consumes 45% of all the
electricity the mill uses so improving its
energy consumption by 5% makes a huge
difference.”
Lauri Raid, Chief Technology Officer
Performance
Results:
Brightness variability reduced 48%
CI02 consumption reduced 8.7%
Temperature regulation problems resolved
Brightness variation reduced and less chemicals
June 12, 2016 © Valmet43
Burgo Ardennes mill, Belgium
Background• The Burgo Ardennes mill produces 400,000 TPY of mixed
hardwood bleached kraft pulp
• Some pulp is consumed in the integrated coated paper mill and
the remainder is sold externally
Challenge• Stabilize the process and reduce costs
• Planned production rate hikes change process dynamics and
chemical usage
• Continuously improve process stability and chemical usage
Our Solution • Audit defined instabilities, targets and solutions
• Expert application of analyzers and optimizing controls
• Performance Service Agreement
• Remote Support service, 24/7 help available
Valmet implemented measurement and control solutions to solve
variations and lower costs.
“The controls are tailor-made. Valmet’s
report tells us if we are consuming the right
amount of chemicals.”
“We achieve the right brightness at higher
production rates with no off-spec pulp.”
Eric Bazzoni, Production Manager
Pierre Carnevali, Mill Projects Manager
New technology
Results:
Flexible fuel usage without problems
Lower fuel costs and supply security for increased use of biomass
Targets set for lower CO2
emissions has been reached with biofuel utilization
Possibility to use more biofuels
June 12, 2016 © Valmet44
Kuopion Energia Oy, Finland
Background• Kuopion Energia Oy produces district heat for the residents of
the city of Kuopio, thus production reliability is in high priority
• Long term partnership with Valmet
Challenge• Main fuels are peat, woody biomass and other bio based fuels
• At summer time bio based fuels are up to 100 % and all year
around 50% of the fuel consumption
Our Solution • Kuopion Energia’s Haapaniemi 3 power plant took Valmet
FuelDiet® corrosion control solution in to use in 2013
• Real time estimate provided of the remaining lifetime of the
superheaters
• Performance Agreement with remote specialist support
“Now we can use 100 % of biomass. The
FuelDiet® corrosion control system is very
useful for us. With the possibility to use
cheaper fuels the payback time of the system
is around 1 year.”
Peter Seppälä, Production Director
New technology
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