Pulp and Paper sector

Improving equipment reliability in pulp & paper operations

The pulp and paper industry operates in extreme conditions, where high temperatures, corrosive chemicals, and mechanical stress push equipment to its limits. From digesters and refiners to dryers and conveyors, every machine must perform reliably to maintain efficiency and quality. Yet, unplanned downtime can cause costly disruptions. Smart condition monitoring enables data-driven decisions that enhance efficiency and profitability.

For leading manufacturers, this strategic approach

  • minimises downtime
  • maximises asset life
  • supports long-term operational success.

 

Reliability insights

0%

equipment failures result from incorrect or insufficient maintenance.

0%

manufacturers still depend on reactive maintenance approaches.

0%

operating expense is maintenance, a significant overage relative to other industries

0

bearing roll failure on the paper machine can cause the whole process to stop for many hours.

Why is condition monitoring critical for the pulp and paper industry?

  • Reduces downtime in key pulp and paper machines like digesters and paper machines.
  • Enhances equipment reliability, ensuring consistent performance of critical components.
  • Enables predictive maintenance, shifting from reactive to proactive care for machines like refiners and dryers.
  • Cuts maintenance costs by preventing breakdowns in systems such as conveyors and turbines.
  • Supports steady production and consistent product quality across the entire manufacturing process.

Top 5 Critical equipment for reliable pulp & paper operations

Pulp digesters play a critical role in breaking down raw materials through high-pressure chemical treatments. However, exposure to extreme temperatures, corrosive substances, and mechanical stress makes them prone to wear and degradation. To maintain reliability, mills must monitor vibrations to catch misalignments early, track temperature fluctuations to prevent overheating, and use advanced inspections to detect corrosion before structural damage occurs.

 

Paper machines are a highly critical and challenging equipment to monitor. A single failure can cause the whole factory to stop. the process operations induce variable conditions (paper speed, diameter …)  that will influence the machine vibrations and makes it difficult to monitor without dedicated technology. Additionnally the harsh environment requires specific robust hardware able to withstand the temperature and humidity.

Boilers generate steam required for various processes, but their reliability hinges on maintaining stable combustion and fluid flow. To prevent inefficiencies, increased emissions, or failures, mills must monitor feed water pumps and fans, track pressure and temperature in real time, and optimise fuel efficiency through predictive analytics.

Turbogenerators supply the electricity needed to keep the plant running, making their maintenance a top priority. Unexpected faults can lead to major power losses and disrupt production.  To prevent costly disruptions, mills should use online monitoring to detect early faults, analyse lubrication quality to prevent wear, and leverage remote diagnostics for real-time assessments and timely interventions.

Material handling equipment, including conveyors and chip pumps, facilitates the smooth transfer of raw materials and finished products. Continuous movement leads to mechanical wear and potential blockages. Mills can prevent failures by monitoring belt and chain health, analysing wear particles to catch friction issues early, and optimising load distribution to minimise strain and extend equipment life.

Acoem’s key technologies to ensure operational efficiency

  • Acoem MCT™ (Machine Condition Tracking): Designed for use with Eagle and MV-x systems to monitor equipment in dynamic environments.
  • Smart Anomaly Detection AI: Cutting-edge analytics for precise fault identification and prediction, minimising unplanned downtime.
  • Shock Finder™: Quickly detects abnormal vibration patterns, enabling immediate corrective actions to prevent equipment failures.

How can Acoem help?

Acoem’s reliability services offer essential tools for food and beverage manufacturing teams to enhance operational efficiency and reduce downtime. These services include:

  • Health assessments for critical equipment like pulp digesters, pumps, and motors, enabling early failure detection.
  • Precision alignment and calibration for rotating machinery, improving performance and reducing wear in paper machines and refiners.
  • Dynamic balancing of fans and blowers, preventing unbalanced loads in dryer sections and ventilation systems.
  • Advanced troubleshooting using real-time data to diagnose and resolve issues in key machinery.
  • Leak detection for compressors and blowers, minimising downtime in material handling and processing equipment.

By integrating these services into your operations, Acoem helps boost reliability, extend equipment lifespan, and enhance overall productivity.

Actionable data 24/7

Data collected by any means, portable, wireless, or real time, are all reviewed and analysed by our remote Advisor experts, enabling 24/7 actionable information availability in NEST Vision.

Discover NEST Vision – the latest, cutting-edge addition to Acoem’s NESTi4.0 platform, engineered to optimize the reliability and performance of wind energy assets. With NEST Vision, you can monitor critical components 24/7, access expert-certified diagnostics instantly, and make data-driven decisions to reduce downtime and enhance operational efficiency.

Through its seamless connection and intuitive dashboard, NEST Vision consolidates vital data sources, including vibration, thermography, ultrasound, delivering a comprehensive, real-time view of your wind turbines’ health. Supported by the advanced analytics of NESTi4.0, NEST Vision transforms complex data into clear, actionable insights that maximize uptime, operational precision, and strategic asset management.

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Maximising uptime in the paper industry with Advisor

In a sector where every hour counts, Advisor ensures no gaps in your maintenance programme. Expanding beyond vibration and alignment, it integrates predictive technologies like motor testing, oil analysis, and thermography. Our experts help you eliminate recurring failures and optimise asset performance—so you set the targets, and we help you achieve them.

Advisor is an individually tailored, custom-designed condition-based maintenance strategy. It seamlessly integrates into your organisation’s existing maintenance program to increase asset integrity and availability using a wide selection of user-friendly wireless, portable, offline and online tools for data collection and AI-driven analysis complemented by human expertise.

Advisor prioritises your maintenance schedule by identifying what actions need to be taken, when and for how long to achieve the highest level of asset reliability.

Advisor provides a world class reliability program efficient at 100% since day one.

Meet Advisor

Automated and easy data collection solutions

Limited resources often make it challenging to conduct the necessary data collection for predictive maintenance. Acoem addresses this with automated monitoring solutions featuring wireless connectivity to protect critical assets. Additionally, our user-friendly, app-based measurement tools, such as the Machine Defender solution, provide on-demand assistance to operators—eliminating the need for in-depth vibration analysis expertise while ensuring efficient and accurate condition monitoring.

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Precision alignment matters

Precision laser shaft alignment is crucial for maintaining the efficiency and lifespan of rotating machinery in the paper industry. Misalignment is a leading cause of equipment failures, increased energy consumption, and shortened component life. Acoem’s laser alignment tools offer precise, quick, and easy alignment, helping to prevent costly downtime and reduce maintenance costs. With mobile guidance, we ensure accurate alignment every time, contributing to more reliable and cost-effective operations.

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Production quality monitoring with MV-x

Vibration analysis not only predicts failures months in advance but also helps detect and prevent production quality issues in the sensitive paper manufacturing process. Environmental vibrations can impact product quality, making real-time monitoring essential.

MV-x, the next generation of AI-enabled vibration analysis, leverages real-time edge computing to pinpoint the source, direction, and intensity of vibrations. More importantly, it provides condition monitoring users with a seamless Industry 4.0 experience, enhancing predictive maintenance and ensuring optimal production quality.

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Anticipation: Our condition monitoring advantage

Stay Ahead with Acoem’s Technology

Through advanced monitoring systems, detect issues before they disrupt mining operations:

  • Wireless Monitoring: Seamless installation for conveyor belts and mobile equipment.
  • Real-Time Insights: Early fault detection minimises downtime.
  • NEST Vision:  A comprehensive monitoring solution combining portability, wireless capabilities, and online real-time data analysis to ensure maximum flexibility and efficiency. All in one (portable, wireless, online)
  • Accurex AI : Acoem’s cutting-edge AI-powered diagnostic technology, leveraging expert-approved data to deliver precise, automated fault detection and actionable maintenance insights.

Discover Accurex

Avoiding costly downtime in paper production

Maximise uptime, minimise costs
A global leader in the paper industry partnered with Acoem to prevent unplanned downtime and reduce maintenance costs. By deploying advanced condition monitoring solutions, the company achieved significant savings:

  • Early fault detection: Acoem identified bearing failures before they escalated, allowing for planned interventions.
  • Reduced repair costs: Predictive maintenance prevented major breakdowns, cutting expensive emergency repairs.
  • Increased equipment lifespan: Proactive monitoring extended machine longevity, optimising ROI.
  • Minimised downtime: Preventing unexpected failures ensured continuous production and reduced revenue losses.

With Acoem’s expertise, the company safeguarded its operations, reinforcing efficiency and profitability in a highly competitive industry.

Read the full case study

Optimising paper machine reliability with Acoem

Proactive monitoring, proven results
A leading paper manufacturer enhanced its machine reliability and reduced maintenance costs with Acoem’s advanced vibration monitoring solution. By implementing continuous monitoring, the company achieved significant operational improvements:

  • Early fault detection: Identified bearing and component wear before failures occurred, preventing costly breakdowns.
  • Optimised maintenance scheduling: Data-driven insights enabled planned interventions, reducing unplanned downtime.
  • Extended equipment life: Proactive maintenance increased machine longevity, maximising return on investment.
  • Improved operational efficiency: Reliable equipment performance ensured consistent production output.

With Acoem’s predictive maintenance technology, the manufacturer strengthened its reliability strategy, ensuring smooth and cost-effective operations.

Read the full case study

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