Case studies

FMW will supply the northern Finnish customer with four fully automatic pulper feeding lines with a total capacity of 2,700 tons of “virgin fiber bales” per day. Three production lines are designed for processing so-called „jumbo bales“ with a total capacity of 123 bales per hour. The fourth line is directed for the preparation and processing of so-called „export bales“ (market pulp). This can be adapted for a capacity of 220 bales per hour in the future.

In order to make the recycling of the wire coils from the eight dewiring machines as efficient as possible, they are collected by a fully automatic magnetic conveyor belt system and transported to a collection container.

„We are very pleased that Stora Enso has once again chosen our solution. The order further expands our existing partnership and reinforces the successful commissioning of a similar plant in 2022,“ said Managing Director for Sales and After Sales and Services Martin Größ from FMW. With its own developed process technology and automation based on the know-how of more than 150 references worldwide, FMW stands out especially for innovation, quality and flexibility. “For FMW it’s another important step to further strengthen its market position for pulp bale handling systems.”, says Managing Partner Felix Sorger.

About the customer Stora Enso

Stora Enso is a leading supplier of renewable products in packaging, biomaterials, wooden construction and paper and one of the largest private forest owners in the world. Stora Enso’s strategy is that everything made from fossil materials today can be made from a tree tomorrow. Stora Enso employs about 22,000 people and had sales of 10.2 billion euros in 2021.

Problem

The paper manufacturer encountered the following operational challenges in their production process:

• Excessive biocide consumption to control microbial growth
• Frequent defects such as holes in paper, compromising product quality
• Increased potential for microbial growth due to water system demands
• Noticeable biocide odor impacting the production environment due to high dosage levels

These issues not only led to inefficiencies but also increased overall operational costs.

Solution

To address these challenges, the paper manufacturer adopted Bansan SCD as a comprehensive slime control solution. Key steps included:

• Integration of Bansan SCD as a single-component system for controlling slime formation
• Application across short and long circulation systems to ensure broad-spectrum microbial control
• Optimization of free chlorine levels to maintain system cleanliness while controlling costs
• Complete replacement of DBMPA, resulting in a streamlined and effective treatment process

The implementation of Bansan SCD was seamless, utilizing existing dosing infrastructure with minor adjustments.

Results

The adoption of Bansan SCD delivered measurable improvements:

• Reduction in biocide dosing requirements by 67–74%, minimizing chemical consumption costs
• Achieved stable chlorine levels within the system, effectively inhibiting microbial regrowth
• Eliminated biocide odors, ensuring a cleaner and more comfortable production environment
• Significant improvement in paper quality, reducing defects such as holes caused by microbial activity
• Enhanced operational efficiency, lowering microbiological contamination to target levels

Additionally, the customer was able to cut down biocide costs by 35% on a yearly basis, leading to substantial financial savings. This reduction highlights the effectiveness of optimized biocide dosing and improved system performance

Benefits

Bansan SCD brought significant advantages to the manufacturer:

• Cost Efficiency: Reduced biocide consumption led to annual cost savings
• Optimized Performance: Improved microbiological control, preventing contamination risks and maintaining system stability
• Environmental Benefits: Lower chemical usage aligns with sustainability targets while maintaining high efficiency
• Improved Workplace Conditions: Elimination of odors created a better production environment for workers

The transition to Bansan SCD demonstrates how advanced water treatment technologies can provide benefits in demanding industrial environments. Bansan SCD not only resolved critical operational challenges but also set a new standard for cost-effective and sustainable slime control.

The need to clean a process line or unit may be related to maintenance work or inspections. It is essential to ensure that the planned work can be carried out in a safe and properly cleaned environment.

The use of steam is recommended in many cases, but it is not always possible. On the other hand, the use of steam alone is not always sufficient. In such cases, cleaning can be enhanced by adding chemicals to the steam or by using liquid chemical cleaning.

Banmark has delivered cleaning projects for challenging side stream processes.

We support our customers from the very beginning. Planning includes analytics and selecting the appropriate cleaning method, including dosing systems and chemistry. We also have expertise in designing and coordinating complex projects to fit our customers’ overall schedules. We tailor the appropriate cleaning method to meet our customers’ needs

Problem

The DD-Washer experienced significant scaling within its filtrate channels, leading to restricted flow rates, reduced washing efficiency, and lower throughput. The resulting production losses and heightened risk of equipment failure created recurring operational challenges.

Solution

• Implemented intensive cleaning procedures using a combination of high-strength acid solutions and complexing agents to dissolve BaSO4 deposits

• Conducted combinatory pre- and post-washer cleaning protocols twice a year to maintain performance

• Adjusted chemical formulations to align with specific scaling challenges in the system

Results

• Successfully restored the DD-Washer’s operating efficiency with deposits nearly eliminated

• Improved throughput capabilities and water removal efficiency

• Reduced the risk of equipment damage from scale-induced stress

Benefits

• Optimized System Performance: Reclaimed washer efficiency ensured smooth operation.

• Cost Savings: Preventative cleaning eliminated the need for costly unplanned downtime

• Improved Longevity: Prolonged the lifespan of washer components through consistent maintenance

• Sustainability: Improved washing efficiency led to lower energy and water consumption during operation

Problem

Contaminants such as resin and extractives commonly accumulate within short circulation systems over time. These deposits can lead to mid-cycle process interruptions, defects in the final product, and machine performance issues. Frequent stoppages caused by dirt flushes from headboxes further decrease profitability by disrupting workflows.

Solution

• Performed comprehensive monthly base cleanings with specially developed industrial detergents
• Introduced two annual intensive cleaning cycles using powerful cleaners tailored to dissolve organic and inorganic deposits
• Customized cleaning protocols based on the specific types of contaminants

Results

• Achieved consistent product quality with minimal contamination-related defects
• Extended machine operating cycles without interruptions due to resin and extractive buildup
• Enhanced operational predictability and reduced unscheduled downtime through carefully scheduled cleaning cycles

Benefits

• Consistent Production: Regular cleaning stabilized process performance across cycles
• Higher Uptime: Reduced downtime thanks to effective impurity control
• Better Quality Output: Improved product appearance and structural quality due to reduced contamination
• Cost Efficiency: Lower maintenance expenses and extended equipment lifespan ensured cost-effective production

Problem

Mechanical pulp production plants facing recurring issues of:

• High formation of inorganic deposits, particularly calcium and sulfate, within evaporation plant units
• Reduced efficiency in condensate production
• Increased fouling potential, leading to costly and frequent cleaning efforts
• Difficulties in maintaining optimal water balance across the mill processes

These conditions elevate operational costs and disrupt mill efficiency, necessitating proactive remediation.

Solution

A comprehensive solution was developed by integrating targeted inorganic deposit control with cutting-edge tools and expertise across multiple domains:

• Custom Chemical Solutions: Precise chemical treatments tailored to reduce deposit formation and scaling
• Advanced Analytics and Modelling: Real-time system evaluations powered by data analysis and predictive algorithms to forecast future behaviour
• Collaborative Expertise: Combining knowledge in chemistry, analytics, modelling, and process optimization to deliver a synchronized approach

Results

Implementing these solutions led to measurable and impactful outcomes:

• Condensate production increased by 5%
• Cleaning and detergent costs were reduced by 13%
• Condensate output became 20% more efficient relative to cleaning chemical consumption
• Process behaviour became easier to predict, enabling proactive system optimization

Benefits

The results translated into multiple tangible benefits for pulp mills:

• Enhanced Efficiency: Improved condensate production and reduced fouling ensure smoother operations
• Cost Optimization: Savings in cleaning and chemical expenditure lower operational costs
• Confidence in Planning: Predictive insights enable mills to anticipate and mitigate future challenges effectively
• Sustainability Gains: Reduced chemical consumption and enhanced water balance positively impact environmental goals

By leveraging these advanced solutions, mills can create sustainable, cost-effective systems while achieving greater operational reliability