SMART® Technology is the world’s first system for dynamic measurement of nip performance.
Press section efficiency is largely
dependent upon contact uniformity
in the press nip. Yet, improper cover
crowns, biased loading, uneven roll
cover wear and uneven fabric wear
can all cause non-uniformity— leading
to costly sheet breaks, reduced
paper quality, increased costs and
decreased roll cover or fabric life.
Traditional tools used to measure
nip performance require machine
downtime and data extrapolation to
obtain a snapshot used to forecast
operating conditions. There has never
been a way to reliably monitor the
response of the nip profile to changing
machine conditions. Until now.
SMART Technology employs a
proprietary embedded sensor system
to extract data from the roll cover
during machine operation. For the first
time, machine operators get real-time
knowledge of true operating conditions.
Real-time knowledge provides the
ability to make on-the-run adjustments
and the power to optimize production,
reduce energy consumption and
control costs.
How it works
A series of sensors is embedded
across the width of the roll cover,
providing a continuous flow of data
across the entire nip. The sensors
are monitored by head-mounted
electronics that rotate with the roll
and transmit data wirelessly to a
dedicated computer. A custom
operator interface provides dynamic
monitoring of the pressure profile,
pressure profile standard deviation
and roll speed. The system also
provides a log of past nip data.
The benefits of
real-time knowledge
Armed for the first time with
accurate real-time knowledge of
nip performance, the operator can
adjust operating parameters and
make corrections to the moisture
profile exiting the press. The benefits
can include an improved nip profile,
extended cover life, reduced
downtime, lower consumption of
materials, reduced energy costs
and early warnings of cover failures.
Years in development, SMART
Technology is now field proven
and providing documented results.
Contact us for more information.
Case Scenario 1
Problem
Chronic non-uniform profile (+2.7% higher on the
back side) leaving 3rd press
Resolution
SMART® Roll identified CD load bias at equilibrium
Corrections made
Value
Drying costs reduced 5.2%
Drying costs = $59/ton
Period = 60 days
Production = 978 TPD $180,157
978 TPD x 60 days x $59/ton x 0.052
Machine Type:
Beloit Trinip
Grade:
Uncoated Free sheet
Basis Weight:
75 GSM (20 lb/1300 sqft)
Speed:
1219 mpm (4000 fpm)
Load:
123 kN/m (700 pli)
Trim Width:
6.75 m
Case Scenario 2
Problem
Excessive sheet breaks (12+/day)
Resolution
SMART® Roll identified dynamic profile
problem in 1st press
Corrections made
Value
Breaks reduced from 12/day to 0.3/day
Production = 730 TPD
Avg. break time = 14 minutes
Incremental profit = $40/ton $994,000 / year
7.1 ton/break x 10 breaks/day x
350 days/year x 40$/ton
Machine Type:
LNP w/ Shoe Press
Speed:
500 mpm (1650 fpm)
Basis Weight:
99-176 lbs/3000 ft2 161-287 GSM
Grade:
Uncoated Plate to Coated
Cigarette Board
Load:
105 kN/m (600 pli)
Trim Width:
5.7 m
Case Scenario 3
Problem
Excessive starch usage in size press
Resolution
SMART® Roll identified peak pressure
variations
Load corrections made
Value
Starch consumption reduced by 5%
Production = 864 TPD
Starch reduction = 5%
Starch cost = $22/ton $312,682 / year
864 TPD x 350 days/year x
$22/ton x .047
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