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Affordabable – Dependable – Continous: Consistency & Freeness Monitoring for Molded Pulp Manufacturing

January 29, 2024

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Better Tools for the Delicate Balance in Molded Pulp Processes

In the competitive world of molded pulp manufacturing, maintaining the delicate balance of consistency and freeness is key to high-quality output and operational efficiency.

WeHAP offers a game-changing approach with the ProEye CS and ProEye 100, offering molded pulp producers an affordable and dependable solution for continuous monitoring of these crucial parameters. 

Operators in a molded pulp production line are tasked with several critical tasks and Continuous measurement of pulp consistency and freeness significantly aids in improving the execution of these tasks.

ObjectiveCritical TaskProEye Impacted Control Actions
Maintaining Product QualityEnsuring uniformity in product weight, strength, and surface characteristics.Adjust the pulp refining process based on freeness measurements to achieve desired fiber characteristics. Modify the pulp mixture ratio or additives based on consistency data to maintain the target product specifications.
Optimizing Raw Material UsageEfficiently using fibers and additives to reduce waste and cost.Fine-tune the amount of water and raw materials in the slurry based on consistency levels to ensure optimal usage. Adjust refining intensity or duration based on freeness levels to prevent over-refinement or under-refinement of fibers.
Controlling the Production ProcessAchieving a smooth flow through the forming, pressing, and drying stages.Regulate the flow rate and pressure of the pulp slurry in the machinery according to consistency measurements to prevent clogging and ensure smooth operation. Modify dewatering pressure and drying temperatures based on freeness and consistency data to optimize the drying process and reduce cycle times.
Ensuring Equipment EfficiencyMaintaining machinery for uninterrupted operation and longevity.Use consistency data to prevent the slurry from being too thick, which could strain pumps and pipes, leading to wear and tear. Monitor freeness to ensure that the fiber properties are within a range that doesn’t lead to frequent clogging or excessive wear on screens and molds.
Reducing Downtime and MaintenanceMinimizing the frequency and duration of machine stoppages for repairs or adjustments.Implement predictive maintenance schedules based on trends observed in consistency and freeness measurements, addressing potential issues before they lead to downtime. Adjust process parameters proactively in response to shifts in consistency and freeness measurements to prevent operational issues.
Managing Water and Energy UseReducing consumption of water and energy for sustainability and cost savings.Optimize water usage in the pulp slurry and during the dewatering stage based on consistency measurements, reducing the need for excessive drying energy. Adjust process parameters such as heating and vacuum levels in the drying stages based on freeness data to enhance energy efficiency.
Adapting to Variability in Raw MaterialsAdjusting the process to accommodate changes in raw material quality or type.Analyze consistency and freeness trends to identify changes in raw material properties and adjust the process accordingly to maintain product quality. Adapt the use of additives, refining settings, and water content based on continuous measurements to compensate for variations in raw material quality.

ProEye LED-strobing for accurate measurement

The ProEye CS and ProEye 100 utilize advanced strobed LED technology to provide real-time, accurate measurements of pulp properties. This continuous monitoring allows for immediate adjustments, ensuring the pulp mixture maintains the perfect balance for optimal product quality. With these tools, WeHAP empowers manufacturers to minimize waste, reduce downtime, and enhance the consistency of their products, aligning with our mission to provide innovative solutions that meet the industry’s needs.

Impact of Continuous Pulp Consistency and Frequency Measurement

Consistency refers to the concentration of fiber in the water, expressed as a percentage. Freeness, a parameter that indicates the degree of pulp fiber refinement and its readiness to drain water, directly impacts the pulp’s characteristics and the final product’s properties. Continuous pulp consistency and freeness measurement in a molded pulp production line is fundamental to ensuring efficient operations, optimal product quality, and resource management. Here’s how continuous freeness measurement benefits a molded pulp production line:

BenefitProEye CSProEye 100
QualityContinuous Cs% enables real-time adjustments to ensure that the pulp consistency remains within the desired range, positively impacting density and strength, leading to uniform and high-quality end productsMaintaining the desired level of fiber refinement ensures that the pulp has the right characteristics, such as porosity and absorbency, essential for producing high-quality molded pulp products. Continuous freeness monitoring results in consistent product quality across different production batches.
Process ControlOperators can make immediate adjustments to the production process, which is essential for maintaining the efficiency of the molding and drying processes.
Energy and Resource SavingsProper consistency management ensures that the slurry is neither too thick, (more energy to pump and process), nor too thin (drying time and energy)Optimizing freeness helps in faster dewatering process during the molding and drying stages leading to shorter cycle times, higher throughput, and reduced energy consumption, as less energy is required to dry the products.
Reduced Downtime and MaintenanceCorrect consistency minimizes wear and tear on machinery due to inappropriate slurry thickness, leading to less downtime for repairs and maintenance. 
Waste Minimization:Continuous control reduces the likelihood of producing off-spec products decreasing waste and improving the overall yield.By fine-tuning the pulp properties through continuous freeness measurement reduces the occurrence of defects and rejections, improving the overall yield of the production line.
Cost EfficiencyOptimizing consistency achieves significant cost savings through reduced raw material and energy usage, less waste production, and lower maintenance costs.Reduced Material and Water Usage:
Environmental ImpactBetter consistency control contributes to the environmental sustainability of the molded pulp production process aligning with demand for eco-friendly practices and productsProper control of freeness can reduce the need for excessive water leading to lower water consumption, less wastewater production, and minimize the overuse of raw materials by avoiding over-refinement of fibers.

Cost-Effective and Reliable Solutions

WeHAP understands the importance of cost efficiency in manufacturing. The ProEye CS and ProEye 100 are designed not only for their technical prowess but also for their affordability. By investing in these monitoring systems, producers can expect a significant return on investment through improved resource management and reduced operational costs, embodying our slogan “We Have A Plan” in providing practical, cost-effective solutions for the industry.

Join the WeHAP Community for Sustainable Innovation

Embracing the ProEye technology means joining a community dedicated to sustainable, efficient manufacturing. For more information on how the ProEye CS and ProEye 100 can transform your operations, contact [email protected], or to dive deeper into the technology with a subject matter expert, email [email protected].

Don’t miss out on the latest innovations in molded pulp manufacturing. Subscribe to our newsletter for updates on cutting-edge technologies and practical insights from WeHAP. Together, we can achieve sustainable manufacturing excellence.

With WeHAP’s ProEye CS and ProEye 100, the future of molded pulp manufacturing is here. Affordable, dependable, and innovative, these monitoring solutions are your key to unlocking efficiency and quality in your production processes. Subscribe now and take the first step towards a more sustainable and profitable operation with WeHAP.

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