ExpertTune's software saves Kruger Paper $1 million per year

Trois-Rivieres, Quebec, Canada—Plant personnel at the Kruger Wayagamack facility recently reported that ExperTune's PlantTriage automatic diagnostic software has increased efficiency of their #4 paper machine by 2% per year, which corresponds to more than $1 million annually.


Trois-Rivieres, Quebec, Canada— Plant personnel at the Kruger Wayagamack facility recently reported that ExperTune 's PlantTriage automatic diagnostic software has increased efficiency of their #4 paper machine by 2% per year, which corresponds to more than $1 million annually.

Kruger started up its new paper machine in 2003, and installed PlantTriage to help with fast startup. PlantTriage helped the facility surpass its planned startup curve by three months. The mill's manager reported it was one of the best startups ever in Kruger's history.'

Within two weeks of receiving the software, Kruger installed it and was receiving diagnostic information. These diagnostics identified trouble spots in the plant, and reportedly prevented at least three shutdowns in the paper machine's early startup phase. 'The paper machine start-up began on Nov. 1, 2003, and we made the first ton of light-coated paper on Nov. 7, 2003,' says Kruger's production superintendent. 'Within one week, we were able to produce the final paper for the grades we wanted.'

However, the software's benefits reportedly didn't end at startup. Kruger's use of PlantTriage also produced a 2% annual increase in paper machine efficiency. 'We're working on a project to install PlantTriage in the rest of our plant, where we have the Kraft mechanical pulp process, secondary treatment, and all the plant's other processes,' adds Kruger's instrumentation su-pervisor. 'We want to add about 700 PlantTriage control loops to monitor all our process sequences. Our goal is to be able to optimize the whole plant with PlantTriage before the end of 2004.'

Established in 1986, ExperTune produces optimization software tools, which run in thousands of plants worldwide. PlantTriage is an automatic diagnostic system for the entire plant, ensuring optimal operation. The company's analysis tools include simulation, modeling, robustness, linearization, valve wear analysis, pH linearizer, time series analysis, multivariable, statistical, frequency response, and PID tuning tools.

A video documentary explaining Kruger's efficiency project and fast startup is available from .

Control Engineering Daily News Desk
Jim Montague, news editor

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