Paper360 - November/December 2017 - 35

the manufacturing process. Cellulose can
be broken up relatively easily, but lignin is
much more tough and fibrous, making it
much more difficult to process. The goal at
Fortress was to extract the lignin and send it
to the recovery boilers so it could be burned
for steam-based electricity.
To perform the necessary extractions to
create high-quality dissolving pulp and generate the steam energy from lignin, Fortress
installed a completely new cooking department
in 2011 and cogeneration plant in 2012. It was
here that the Fortress team found themselves in
uncharted terrain. Between new quality benchmarks, and an enormous investment in mill
acquisition, new equipment, and retraining, the
Fortress team was taking on a massive risk, and
there were no other experts to call for help. Team
members had to work through all challenges
internally and the mill could not afford to fail.
"The team was pretty adamant when we
started that we needed a good data management
system to support the success of our mill," said
Daniel Tremblay, information services superintendent at Fortress Specialty Cellulose.
Since 2002, Fortress Specialty Cellulose had
used asset data from the OSIsoft PI System to
monitor operations in its mills. Given their
prior experience with the PI System, Fortress
opted to use the same infrastructure to monitor all assets within the mill. In conjunction
with this installation, Fortress personnel
attended a three-day workshop called AssetBased Jumpstart, which is an in-depth seminar
designed to help PI System users identify strategic opportunities for their implementations.
After identifying and setting goals, the new
influx of real-time data allowed mill employees to gain visibility into these processes and
overcome many of the challenges associated
with the changes.
Initially, Fortress experienced substantial
water hammer issues that resulted in violent
line shaking within the new cooking plant.
The water hammer caused several line failures and resulted in safety hazards for mill
operators. At times, these water hammer incidents would number as many as 100 per day.
With the help of daily notifications from the
PI System, Fortress could identify the equipment, digesters, and sequences that were at
risk of a water hammer issue. From there, the
mill installed instruments on the cooking line
to detect vibrations and analyzed the velocity

meter data in the PI System. Data was then
correlated with the vibrations to identify the
root cause so the problem could be fixed. Now,
water hammer incidents have decreased by 97
percent and, at most, the mill experiences only
one or two per day.
The conversion was a long and sometimes
arduous process, but after putting the right
guardrails on the plant conversion for problem-solving, the conversion was a success.
Since the initial conversion, Fortress is using
the PI System to monitor day-to-day activities
through their five-step process for continuous
plant improvement. By defining, measuring,
analyzing, improving, and controlling all parts

of the plant floor, the plant is thriving. "Today,
we now produce more than 170,000 tons of
dissolving pulp and generate 24 megawatts
of electricity," said Tremblay.
PRODUCTION OPTIMIZATION:
EVERGREEN PACKAGING
Evergreen Packaging is a fiber-based food
and beverage packaging manufacturer that
operates multiple facilities around the world.
Six years ago, Evergreen noticed that finished
paper rolls were becoming lapped, or stuck,
during the slitting and winding process,
resulting in significant costs due to lost product. Evergreen embarked on a journey with

Overview of the winder at Evergreen Packaging.

Using the data system, Evergreen mill operators are trained to identify optimal production points and
adjust the system accordingly; this has led to a 60 percent reduction in off-quality product.

Paper360ยบ NOVEMBER/DECEMBER 2017

35



Table of Contents for the Digital Edition of Paper360 - November/December 2017

Setpoint
Over the Wire
Rebuilds and Conversions
Proud to be a Papermaker
The New Cascades
Operational Data Helps Mills Meet Challenges
Papermaking Best Practices with Vacuum-Dewatering Systems: Part 2
TAPPI Library is an Industry Resource
Managing the Decline of Graphic Paper Demand
TAPPI Journal Summaries
2017 PPI Awards Finalists
TAPPI News
ASPI News
Index of Advertisers
Paper360 - November/December 2017 - Intro
Paper360 - November/December 2017 - cover1
Paper360 - November/December 2017 - cover2
Paper360 - November/December 2017 - 3
Paper360 - November/December 2017 - 4
Paper360 - November/December 2017 - 5
Paper360 - November/December 2017 - Setpoint
Paper360 - November/December 2017 - 7
Paper360 - November/December 2017 - Over the Wire
Paper360 - November/December 2017 - 9
Paper360 - November/December 2017 - 10
Paper360 - November/December 2017 - 11
Paper360 - November/December 2017 - Rebuilds and Conversions
Paper360 - November/December 2017 - 13
Paper360 - November/December 2017 - 14
Paper360 - November/December 2017 - 15
Paper360 - November/December 2017 - 16
Paper360 - November/December 2017 - 17
Paper360 - November/December 2017 - 18
Paper360 - November/December 2017 - 19
Paper360 - November/December 2017 - 20
Paper360 - November/December 2017 - 21
Paper360 - November/December 2017 - 22
Paper360 - November/December 2017 - 23
Paper360 - November/December 2017 - Proud to be a Papermaker
Paper360 - November/December 2017 - 25
Paper360 - November/December 2017 - 26
Paper360 - November/December 2017 - 27
Paper360 - November/December 2017 - 28
Paper360 - November/December 2017 - 29
Paper360 - November/December 2017 - The New Cascades
Paper360 - November/December 2017 - 31
Paper360 - November/December 2017 - 32
Paper360 - November/December 2017 - 33
Paper360 - November/December 2017 - Operational Data Helps Mills Meet Challenges
Paper360 - November/December 2017 - 35
Paper360 - November/December 2017 - 36
Paper360 - November/December 2017 - 37
Paper360 - November/December 2017 - Papermaking Best Practices with Vacuum-Dewatering Systems: Part 2
Paper360 - November/December 2017 - 39
Paper360 - November/December 2017 - Managing the Decline of Graphic Paper Demand
Paper360 - November/December 2017 - 41
Paper360 - November/December 2017 - TAPPI Journal Summaries
Paper360 - November/December 2017 - 43
Paper360 - November/December 2017 - 44
Paper360 - November/December 2017 - 45
Paper360 - November/December 2017 - 2017 PPI Awards Finalists
Paper360 - November/December 2017 - 47
Paper360 - November/December 2017 - TAPPI News
Paper360 - November/December 2017 - ASPI News
Paper360 - November/December 2017 - Index of Advertisers
Paper360 - November/December 2017 - cover3
Paper360 - November/December 2017 - cover4
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