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TTC - Total Tissue Capability
Driving cost savings through process improvement

Authors: Roland Berger, Product Manager Mütek™ LAB & ONLINE, BTG Instruments GmbH
Ian Padley, Tissue Applications Mgr – Europe, BTG Eclépens S.A.
Jeff Peters, Tissue Applications Mgr – Americas, BTG Americas Inc.

Understanding and controlling wet end variability is the key to achieving a consistent crepe operation and in some cases realizing the full potential of a high-performance crepe blade strategy. BTG’s Total Tissue Capability concept has developed a total control strategy utilizing a range of on-line instrumentation, off-line lab studies and detailed tissue chemistry and crepe application competencies to map the entire tissue process from wet end to converted product. Implementation of a process improvement plan defined by this survey can result in significant consumable cost savings, improved asset efficiency and enhanced delivery of tissue quality.

The benefits of automated control strategies for both stock preparation and the wet end are well described in applications such as fine paper, LWC and other DIP-containing grades. In tissue production however, control solutions using instrumentation are not yet widely applied despite their proven impact on the heart of tissue production, the Yankee performance.

Tissue consumers expect products of the highest quality. It is possible to achieve quality economically with a well-designed creping process and the use of costly fiber and chemicals, but unfortunately machine settings and adjustments are often made ‘blindly’, not taking into account the strong influences of variations in the fiber quality, grade-specific bleaching chemistry and uncontrolled fines and ash content.

To fully exploit the improvement potential, experience has shown that an integrated approach would offer the solution. Combining creping expertise and wet-end chemistry knowledge will result in cost-effective improvements for the entire tissue process.

The critical process control information is important to ensure a stable operation; but with reduced resources, its collection becomes more difficult. So, now more than ever before, it is time to take advantage of the numerous high-quality, highly reliable on-line transmitters and analyzers that can be used in a closed loop control scheme to optimize chemical consumption, machine performance, sheet quality and profitability. With the reduction in personnel and the significant performance gap seen in most tissue mills, payback for such equipment installations is becoming more easily justified to meet mills’ ROI requirements.

A wide range of instrumentation is available from charge analysis and brightness control to consistency transmitters and drainage control. The BTG approach combines these core competencies with real-time machine data, detailed lab surveys and creping expertise into a Total Control Strategy for process improvement.

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