Pratt industries implementing resource optimization for paper manufacturing facilities using Honeywell DCS integration
Jhon Anderson
May 19, 2021
About Pratt industries
Pratt is one of America's largest corrugated packaging companies and the world's largest 100% recycled paper and packaging company, with more than 6000 highly-skilled, green-collar employees dedicated to the environment and sustainability.
Pratt has a well-established record of sustainable business practices:
- 100% recycled fiber
- Innovative facilities enable less use of fiber due to modern containerboard system
- Reduce consumption of purchased energy.
- Reduce greenhouse gas emissions.
- Reduce water use in our facilities.
- recovery of recyclables - currently more than 3 million tons per year.
Some numbers about Pratt:
- 16 MWH of Electricity
- 5 MWH self generated
- 90 TPH of Steam
- 40 KGPH of Water
- 3500 MMBTU of Natural Gas
- Produce 50 TPH of paper
Goals of the project
- Monitor Changes In Dryness (CID) from section to section
- Monitor energy usage
- Optimize machine speed for quality and production KPIs
Solution
As requested by Pratt experts, Monitoring Changes In Dryness (CID) from section to section along with energy usage will enable process optimization to increase production rate and reduce energy usage. Pratt uses Honeywell DCS to store data collected by sensors across the production line.
Collected metrics
- Grade
- Basis weight
- Machine speed and draw
- Moisture and steam consumption
- Power consumption
- Chemical usage
- Steam consumption Vs condensed per section
- Ambient conditions effects on production rate
- Pressure
- Speed
- Draw
Efficiency KPIs
- KWH / Ton
- Steam Ton / Ton
- Water & Effluent in Ton/ Ton
- Different chemical usages in Pound / Ton
- Basis weight Vs nominal basis weight
- Long and short term speed and grade comparisons
- Real time and historic condensate loss in %
- Change in dryness (CID) in % from section to section
- CID in % per unit of steam usage in a given section
- CID at different production rates and grades
Screenshots
We provide the sensors (temperature, speed, power, flow, pressure, humidity, and radar) or connect directly to existing sensors and controllers. Sensors’ data is instantly and securely accessible from your smartphone or tablet so you can check real-time status or monitor trends. Zira will automatically set alerts for data continuity and quality so you can fully trust the data that you base your decisions on.
Zira gives you full control to create the dashboards of your dreams! Create engaging dashboards that push teams to take action and automatically send messages in the current channels or direct to users. Zira also comes preloaded with dashboard and analytics templates to help you start fast and get things done.
Digitize your manual processes and get notifications, alerts, and real-time data to do the work for you. You can easily set up workflows and streaming alerts for quality assurance, safety, and downtime tracking. Once the processes are flowing, you can replace digital forms data entry with sensor and automated controls to grow the ROI even further.
Give employees the freedom to collaborate and get their feedback over real-time data in real-time. Keep all your data, including employee feedback, comments, and collaboration data in one place which we call a ‘channel’. Leverage channel activities to learn how your teams interact with each other and deploy artificial intelligence to drive consensus and nurture growth.
Put task management into robotic mode and enjoy more leisure time with your team. Task management is a breeze when everything is in one place. Tasks are automatically created from real-time data insights and move through the task pipeline automatically. All you need to do is scroll through the channel feed and enjoy the empty to-do column in your tasks tab.
Jhon Anderson
May 19, 2021
Share:
