Case Study #1 - Increased paper machine production by as much as 11%.
|Challenge: A mill making kraft liner wanted to decrease the cost of its stickies and pitch program and reduce the number of breaks.|
|Solution: Buckman applied Optimyze® Plus at the tower inlet where short fiber and recycled fiber mixed.|
|Result: Paper machine production increased by 11% in one machine and 9.8% in another. Costs were significantly reduced.|
|Return on Investment: US$870,000/year or US$1.81/metric ton|
Case Study #2 - Reduced rejects and impact on the environment.
|Challenge: A mill making recycled medium for corrugated packaging was experiencing a high break frequency with its dispersant program and rejecting a lot of board because of excess dirt.|
|Solution: Buckman replaced the dispersant with a continuous application of Optimyze Plus at the white water tank.|
|Result: Breaks and rejects were dramatically reduced.|
|Return on Investment: US$32,640/year or US$0.68/metric ton|
Case Study #3 - Improved runnability and product quality.
|Challenge: A packaging mill making recycled medium wanted to reduce stickies-related downtime and reduce customer complaints about “grease spots” on the paper.|
|Solution: Buckman applied Optimyze Plus to the waste chest.|
|Result: Monitoring of the approach flow stock showed the number of stickies was reduced by 46% and the size of the remaining stickies was reduced by 82%. The downtime from stickies-associated cleaning and breaks was reduced by approximately 7.3 hours per month. And “grease spots” were significantly reduced in size and number.|
|Return on Investment: US$825,600/year or $4.17/metric ton|
Case Study #4 - Reduced raw material costs.
|Challenge: A cartonboard manufacturer wanted to replace kraft envelope furnish with white ledger to save $220 per ton in raw material costs. But the ink in the recycled white ledger agglomerated, causing black and blue spots on the finished board.|
|Solution: Buckman determined that, in addition to stickies control, Optimyze Plus could prevent ink from agglomerating.|
|Result: Ink spots were eliminated allowing the mill to use the less expensive furnish.|
|Return on Investment: US$547,940/year or US$5.89/ metric ton|
Case Study #5 - Turned a profit in the dryer cylinders.
|Challenge: A mill making liner fluting had to stop the machine twice a day to clean the drying cylinders and fabric, losing valuable production time.|
|Solution: Buckman determined the problem was a build-up of stickies in the dryer section. These were transferred to the paper surface causing breaks during the rewinding operation. Optimyze Plus was applied to the OCC chest.|
|Result: Machine runnability improved dramatically and paper quality was enhanced.|
|Return on Investment: US$241,500/year or US$2.86/metric ton|
Case Study #6 - Minimized downtime and cleaning chemical costs.
|Challenge: A kraft liner mill was having to shut down frequently for scraping and felt replacement.|
|Solution: Buckman began an Optimyze Plus program to reduce downtime and extend felt life.|
|Result: The mill saved approximately 100 minutes of downtime per month as well as $2500 per month in cleaning chemical costs.|
|Return on Investment: US$342,492/year or US$0.63/metric ton|