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QCS for Impregnated paper > Savings potential


Savings potential
One of the main arguments for installing online QCS is in the savings created. Generally speaking the savings are significant for all producers, but they typically vary from producer to producer and depend on a number of things.

In the following we present some rough estimates of savings created by Scienta online QCS on a typical Melamine Impregnation Treater . These estimates assume a number of quality changes (typically several per day) and also that operators have reasonable know-how of their process and the system.

The usage of an online system varies throughout the industry and depends much on the ‘culture’ of the plant in question as well as the age and condition of the Treater. The estimates given are estimates intended as a basis for discussion and further analysis of the production line in question, and should not be considered as promises or guarantees of benefits that will materialize in your application.
Benefit Questions relating to an existing Melamine Treater installation Typical savings. The figure will vary depending on product range and age/condition of Treater
Waste reduction How much has the waste been reduced by %-terms? This clearly depends on how wasteful the process currently is. It also depends on the frequency of product changes. A rough estimate is 0.5%
Raw material savings What are the raw material savings (% of material cost)? 1-2% typically, sometimes more.
Fast product changes How much less 'out of spec' paper is made on changeover (%)? Saving of 10-30 min per product change typrically, depending on how far 'out of spec' the product was initially.
Less web breaks How many web breaks less are there per
day / week / month?		 Typically 2 per day with frequent product changes / start-ups.
Detection of dirt How much less 'out of spec' paper is made without dirt contamination (%)? Dirt build-up on rollers is easier to detect and thus faster to get rid of. Not typically a major issue on most Treaters, but eases maintenance.
Planning downtime What is the improvement in downtime as %? Unscheduled downtime is typically cut in half. The condition of the Metering rolls is easy to monitor and major overhauls may be scheduled better.
Detection line defects What % improvement in line defects? Roller wear an misalignment that go unnoticed with manual checks can be detected. Defects do not occur periodically, thus hard to quantify. Misalignment of rollers can lead to entire production being off spec. We have had one such case.
Less reclamations What is the reduction in reclamations? It depends on the market and your target market. Customers outside own group are more prone to make reclamations , thus it depends on whom you sell to. Reclamations are the worst kind of waste, and their true cost is hard to measure, but avoiding one major reclamation alone can create significant savings. This is particularly relevant for the high end producers.
Improved Quality Standards What % improvement has there been for spec paper? Quality variations, i.e. variation in Resin Weight and Volatile content are typically cut in half.


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