1 way to know, plus how to reduce related risks of costly downtime or wear
Picture this: Your production is below target and your finished product has defects that suggest a profile issue with the pressure roll. What are your options?
Extra Furnish is Deceiving
You may add extra stock to level the profile. The product quality seems to improve – temporarily. When the issue returns or moves, you add a bit more stock and things get better. You’re feeling pretty good because you’ve met your production goal!
The problem seems solved – until your accounting department or supervisor asks why profits are diminishing over past production runs due to:
- excessive furnish usage, and
- higher energy usage.
More Pulp, More Cost
We often help clients in similar situations. If a tissue manufacturer offsets insufficient profile with more pulp, the cause is likely a pressure roll defect. Unfortunately, adding pulp won’t help in the long run.
It’s a vicious cycle of cause and effect:
- The more furnish you use, the greater the cost.
- Adding more furnish increases the basis weight.
- More weight might mean more wear on the felts.
- Added wear leads to machine defects.
- The unplanned maintenance costs, machine downtime and repair costs further affect your bottom line.
Even if you have precise profiling equipment in house, your costs may increase due to excess energy or chemical usage.
Market Research Manager Pierre Bach notes that pulp is 70 percent of a tissue manufacturers’ cost. If your business doesn’t take care of a pressure roll defect, costs will rise.
The Good News
A couple of proactive production and maintenance measures will help. Tissue World Magazine suggests that “machines can run more energy efficiently with fresh water levels reduced to the 7-15 m3 per tonne levels, and the higher recycled water can improve the felt life.”
Regarding maintenance, a consultation with Precision Roll Grinders will help you identify the root cause of your profile problems.
3 Benefits to Your Bottom Line
The combination of cost saving measures and proactive maintenance on your rolls will improve your company’s operations in 3 key ways:
- Maximize uptime/minimize downtime
- Increase yield
- Protect profits
If you suspect that your business is experiencing costly defects in tissue manufacturing, call Precision Roll Grinders or contact us here. Our nationwide team of roll experts understands your business, and can help roll your pulp problems into profits.