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OnEfficiency, OnCumulus, OnView

Efficiency Solutions: Increase production and quality, reduce costs

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Efficiency Solutions

    With our Voith "Efficiency Solutions" OnEfficiency, OnCumulus, OnView, we help you increase production, achieve the desired quality, and reduce costs at the same time - using visualizations, advanced-process controls, and AI-supported optimization tools.

    We believe that Voith, with its extensive technological knowledge, is at the edge when it comes to digitalization in paper manufacturing.
    Andrea Isabella, Partner and Director at Bain & Company

    Advanced process control

      Voith's advanced process controls (APC) increase your profit by producing paper with the targeted quality - at the lowest cost and with the greatest efficiency.

      OnEfficiency.BreakProtect

        Description

        OnEfficiency.BreakProtect

        OnEfficiency.BreakProtect

        OnEfficiency.BreakProtect uses a unique AI algorithm to automatically define break segments (breaks having the same break root causes). For each segment, a solution can be defined – ranging from counter actions applied each time the risk for this break segment increases to one-time optimizations and small rebuilds.
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        Benefits

        Reduce paper breaks and increase production 

        • Automatic identification of break segments
        • Sophisticated analysis tool to identify the cause of breaks and how to prevent them
        • Warning of upcoming breaks including counter measures to prevent them
        • Depending on initial situation, reduction of breaks by 25 to 50% and/or production increase of 1 to 2%

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        OnEfficiency.Strength

          Description

          OnEfficiencyStrength

          OnEfficiency.Strength

          OnEfficiency.Strength combines three modules to create a new generation of advanced process control (APC): virtual sensors (also called soft sensors), model predictive control (MPC), and a cost optimizer.

          The virtual sensors accurately predict quality values that otherwise are only available at the end of each tambour as the result of destructive tests in the lab. This allows the MPC to control the process to continuously reach these values, while the cost optimizer makes sure this happens at the lowest possible cost.

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          Benefits

          Optimum paper quality at the lowest cost

          • Stabilization and optimization of the production process
          • Virtual sensors afford live availability of critical quality parameters, enabling closed-loop control
          • Reduction of quality fluctuation and off-spec production
          • Lower costs

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          Success Story 1

          Improved and stabilized process

          Improved and stabilized process

          Field results Ružomberok PM18​:
          OnEfficiency.Strength lead to improved basis weight and ratio of fiber to ash.
          2,800 tpy fiber savings in the first year, by​ ~ 0.5% basis weight reduction ​and ~ 0.3%-points ash increase.
          READ SUCCESS STORY
          We have been using OnEfficiency.Strength since 2018 to consistently meet quality requirements for stiffness and thickness and thus optimize the paper produced on the PM 18. In the process, we are also reducing our costs, because OnEfficiency.Strength provides optimum control of basis weight and ash content.
          Peter Chlepko, Manager of PM 18 at Mondi SCP Ružomberok

          Success Story 2

          Easy integration, optimized results

          Easy integration, optimized results

          Field results Fabriano PM3​: On Efficiency.Strength lead to significant cost savings that have convinced the customer to use Voith’s digitization expertise for further machines as well. 
          Interview NEXT LEVEL STORY Success Story
          Every day, when in the morning I check the produced paper and I realize that, with OnEfficiency activated, I can reach the results in terms of optimization of the product specifications, that I wouldn’t have reached without OnEfficiency.
          Libero Grandoni, Plant-Paper Machine Manager at Fabriano on what had been the best moment in the project

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          OnEfficiency.DIP

            Description

            OnEfficiency.DIP
            OnEfficiency.DIP optimizes an existing DIP line to create constant DIP quality at minimum cost. The existing flotation is supplemented by additional actuators; new sensors are installed to monitor the quality parameters.
            The DIP quality fluctuations created by incoming raw materials or production changes are reduced by dynamic adjustment of the losses at the washing/flotation as well as real-time optimization of the bleaching chemicals dosage.
            Contact Download PDF brochure Webinar

            Benefits

            Increased yields, lower operating costs

            • Lower chemical and energy consumption
            • Higher yields
            • More consistent DIP quality
            • Faster grade changes

            Contact Download PDF brochure Webinar

            Success Story 1

            OnEfficiency.DIP
            DIP line for newsprint with 170 ktpy
            • yield increase from 77.9 to 79.8%
            • energy consumption reduced from 35 to 32 kWh/t
            • hydrosulfite charge reduced from 0.04 to 0.02%
            • primary ash addition reduced from 28 to 16 kg/t

            Total savings achieved: 1.22 MEUR/year, equaling a cost reduction of 13% or 7.2 EUR/t

            Success Story 2

            OnEfficiencyDIP
            DIP line for newsprint with 350 ktpy

             

            • yield increase from 85.7 to 88.1%
            • energy consumption reduced from 42 to 27 kWh/t
            • peroxide charge reduced from 0.99 to 0.78%
            • hydrosulfite charge reduced from 0.12 to 0.06%
            • primary ash addition reduced from 40 to 23 kg/t

            Total savings achieved: 3.55 MEUR/year, equaling a cost reduction of 22% or 9 EUR/t

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            Advanced process visualization

              Advanced-process visualization is the new way to visualize process data. Cloud-based applications running on OnCumulus provide intuitive user interfaces optimized for the different user groups in a paper mill.

              OnCumulus.Suite

                Description

                OnCumulus.Suite

                OnCumulus.Suite

                OnCumulus.Suite contains four apps: Analyzer, Cockpit, Events and Functions. 
                Analyzer is used to monitor and evaluate historical and live data, e.g. to find the root cause for a problem.
                Cockpit visualizes the current status of the process in a clear and easily understandable way. 
                Events allows to displays and filter different types of events, e.g. for quick trouble shooting.
                Functions allows customers to calculate new values based on existing data. The calculated values are then available for all other applications running on OnCumulus.
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                BENEFITS

                Data, analysis, and visualization at one glance

                • Intuitive web-based tools to easily gather, visualize, and intepret operational data
                • Highly customizable visualization tools to generate useful insights specific to your operation
                • Interconnected apps for maximum data consistency
                • Actionable information to quickly isolate possible production issues and take appropriate measures

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                OnView.VirtualSensorBuilder

                  Description

                  OnView.VirtualSensorBuilder

                  OnView.VirtualSensorBuilder

                  OnView.VirtualSensorBuilder lets you create virtual sensors (soft sensors) quickly and without data analysis skills and display them either immediately via OnCumulus.Suite or in your own visualization tool.
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                  BENEFITS

                  Create soft sensors quickly and without data analysis skills

                  • Fast creation of virtual sensors (soft sensors) - without data analysis skills
                  • Reduction of off-spec production through real-time availability of strength values
                  • Optimized paper quality at lower cost
                  • Faster grade changes

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                  OnView.MassBalance

                    Description

                    OnView.MassBalance

                    OnView.MassBalance

                    OnView.MassBalance allows the real-time visualization of all relevant losses. For each stream, the deviation from the standard operation range is visualized in an intuitive Sankey diagram. If losses rise above a warning threshold – which can be defined for each stream – the corresponding streams in the Sankey diagram will be marked and the operators will receive recommended countermeasures, which also can be individually defined. 
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                    Benefits

                    Visualize and reduce losses

                    • Easy troubleshooting/optimization through real-time visualization of losses
                    • Increased process transparency by making the stream deviations visible
                    • Loss reduction by defining countermeasures for each reject stream

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                    Success Story

                    Reduction of losses

                    Reduction of fiber losses with help of OnView.MassBalance

                    The diagram shows the results from Saica Venizel, with an OCC line with 250 ktpy. Optimization based on the monitoring by OnView.MassBalance lead to ~ 2% fiber (paper for recycling / raw material) savings on average. A “reset” to the initial settings clearly showed the importance and positive effect of continuous monitoring and optimization.
                    Read interview
                    OnView.MassBalance allowed us to save 1.550 tons of fiber* already in the first year after implementation. In the second year the savings increased to 5.350 tons and after some more optimizations, the average now even reached 600 tons of fiber savings per month, compared to the reference period.
                    Fernando Carroquino, Industrial Director SAICA Paper

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                      Performance enhancement & sustainability

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