Paper Technologies

masthead-paper

Tissue Case Histories

View Categories

Case Studies - Tissue Mill #1 - Higher strength. Lower fiber and energy costs.

The Challenge: Maintain tissue strength but reduce fiber and energy costs.
The Solution: Buckman applied a customized Maximyze® program to the thick stock to increase tensile strength. That in turn allowed the mill to decrease refining energy from 330 to 265 kWh/ T and reduce long fiber furnish by 5 .7%, which decreased raw materials cost.
Return on Investment: Refiner Energy Reduction 20% reduction | Raw Material Cost Saving 5.7% reduction
Annual ROI: $138,700
Return on Environment: CO2e Reduction 4.9Kg/T Production
Annual CO2e Reduction: 300 T

Case Studies - Tissue Mill #2 - Drying faster. Running faster.

The Challenge: Obtain a speed increase on a drying limited tissue machine by decreasing the energy required to dry the sheet.
The Solution: Maximyze® was added to the pulper,allowing the mill to reduce both refiner and drying energy, so machine speed could be increased by almost 1%. Reducing energy consumption also cut CO2 emissions. The added tensile strength allowed the mill to substitute with less costly fiber for additional savings.
Return on Investment: Drying Energy - 6% reduction | Refiner Energy - 34% reduction | Machine Speed - 0.9% increase | Production - 1% increase
Annual ROI: $574,200
Return on Environment:
Energy Reduction Grid Electricity 222 Input(kWh) | 0.544 CO2e Conversion Factor | 120.8 CO2e Reduction
Energy Reduction Natural Gas 213Input(kWh) | 0.184 CO2e Conversion Factor | 39.2 CO2e Reduction
Total CO2e Reduction 160
Annual CO2e Reduction: 1401 T

Case Studies - Tissue Mill #3 - Shorter fiber. Bigger rewards.

The Challenge: Use more short fiber without losing strength. Decrease total refining and drying duration and energy consumption.
The Solution: Buckman’s Maximyze® application increased mechanical sheet strength characteristics, which allowed the mill to substitute long fibers with lower cost short fibers in the furnish. Drying and refiner energy was reduced significantly.
Return on Investment: Drying Energy 11% reduction | Refiner Energy 25% reduction | Long to Short Fiber Ratio 12% reduction
Annual ROI: $872,400
Return on Environment:
Energy Reduction Grid Electricity 250(kWh) | 0.544 CO2e Conversion Factor | 136 CO2e Reduction (Kg/h)
Energy Reduction Natural Gas 426(kWh) | 0.184 CO2e Conversion Factor | 78.4 CO2e Reduction (Kg/h)
Total CO2e Reduction (Kg/h) 214
Annual CO2e Reduction: 1874.6 T

Case Studies - Tissue Mill #4 - A more refined operation.

The Challenge: Reduce refining energy applied to the furnish of the air cap and middle layers of a stratified tissue base sheet.
The Solution: Maximyze® helped the mill reduce refining energy nearly 25% while also reducing starch use and limiting dust on the machine and converting operation. Better sheet strength allowed for less expensive fiber, saving the mill $337,905. And energy savings reduced the mill’s environmental footprint.
Return on Investment: Positive returns were realized in the following areas:
• fiber substitution • reduced chemical costs • reduced refiner energy
Annual ROI: $337,905
Return on Environment:
Energy Reduction 88(kWh) 0.544 | CO2e Conversion Factor | 47.8 CO2e Reduction
Annual CO2e Reduction: 352 T

Case Studies - Tissue Mill #5 - Two kinds of tissue. Same outstanding results.

The Challenge: Save refining energy in both bathroom towel and facial tissue production. Increase eucalyptus content without losing quality.
The Solution: Maximyze® worked well in both applications, reducing drying time and refiner energy consumption. Added strength allowed for more eucalyptus substitution.
Return on Investment:
Drying Energy Reduction - Bathroom Towel 3% | Facial Tissue 5%
Refiner Energy Reduction - Bathroom Towel 70 kWh/tonne | Facial Tissue 40 kWh/tonne
Eucalyptus Increase - Bathroom Towel 3% | Facial Tissue 5%
Annual ROI: Bathroom Towel $163,094 | Facial Tissue $144,972
Return on Environment: Refining Energy CO2e Reduction Per Tonne - Bathroom Towel 35 kg/t | Facial Tissue 20 kg/t
Annual CO2e Reduction: Bathroom Towel 840 T | Facial Tissue 320 T

Case Studies - Tissue Mill #6 - Kitchen towel clean-up.

The Challenge: Maintain kitchen towel strength while reducing refining. Decrease sheet drying time and decrease refining energy consumption to speed up production, reduce costs and help simplify the wet end chemistry.
The Solution: Buckman’s Maximyze® application met every goal while reducing the mill’s carbon footprint and saving the mill $709,442.
Return on Investment: Dryer Energy 10% reduction | Refining Energy 29% reduction | Machine Speed 5.6% increase | Production Rate 5.6% increase
Annual ROI: $709,442
Return on Environment:
Energy Reduction Grid Electricity 6,812.4 Savings/day(kWh) |  0.59239 CO2e Conversion Factor |  4,035.6 CO2e Reduction (Kg/h)
Energy Reduction Steam 10,510.6 Savings/day(kWh) |  0.14 CO2e Conversion Factor |  1,471.5 O2e Reduction (Kg/h)
Total CO2e Reduction (Kg/h) 5,507.08
Annual CO2e Reduction: 2010 T

News & Media

Commitment makes the best chemistry.

  

© 2017 Buckman Laboratories International, Inc.