An eco-friendly world-class integrated paper and packaging company subsidiary uses 100% recycled paper to create their products. A circular sustainability model enables them to produce 100% recycled paper and efficiently reuse 100% of the water used in the process by means of state-of-the-art closed circuit zero-waste system. Having accurate and reliable measurements with minimal downtime is a must when you’re actively producing 230,000 tons of paper products every year. Here’s how this paper company identified the issues with their current system and found a more sustainable solution.
Rough clones and the stock prep screen reject line are essential parts of the stock preparation process, designed to remove contaminants from the pulp. Unfortunately, regular maintenance and shutdowns were the norm at this production site. The flush-mounted pressure devices they had been using would experience electronics ingress issues, and the measuring cell would sustain damage over time from normal production processes. Additionally, the lid for the electronics housing kept popping off, further complicating electrical ingress issues.
Customer service for these devices was nonexistent, so, twice a year, these sensors had to be replaced with brand new ones. Within six months they would inevitably experience the same issues. This required periodic shutdowns for setup and recalibration, interrupting production and delaying product shipments to Mexico and Latin America. Without accurate pressure readings, quality, energy efficiency, and performance were compromised.
Plant operators recognized their predicament and spoke with VEGA about their repeated process pressure issues. While the competitor’s devices were not the best option, operators wanted to be sure our sensors would work and would stand the test of time, so a trial was organized with a 4…20mA/HART VEGABAR 82 with a M.44 x 1.25 process connection. VEGA provided the company with a 1 1/2" NPT device, free of charge, and welded it on to their process line. After six months with the new device showing no signs of wear, mechanical issues, or electronic ingress, and providing consistent and reliable measurements, they were ready to purchase their next unit.
Plant personnel were grateful that they no longer had to repeatedly purchase replacement sensors, and the abrasion-resistant ceramic measuring cell proved that it could easily handle the process pressure requirements of the facility. The VEGABAR 82’s 4 … 20 mA/HART signal output was compatible with their current systems, and with easy setup and commissioning via Bluetooth and the VEGA Tools app, it was an easy choice for operators to standardize their processes with the new device.
The staff at this paper plant have gained peace of mind with their latest VEGABAR 82 installation. They no longer need to spend extra money replacing transmitters twice a year. With so many installations across 40 locations in the plant, operators now save tens of thousands of dollars every year the VEGABAR 82s are in operation. Communications and safety have also increased - plant professionals can connect to and troubleshoot their devices from a distance, and the VEGA field service team always has their backs.
Better sensors mean less environmental and monetary waste. Getting the right measurement solutions that align with sustainable business practices is a win-win scenario, and that’s why they chose the VEGABAR 82 to standardize plant processes.