Eliminating the Hidden Losses of Grade Changes
Eliminating the Hidden Losses of Grade Changes
40% Faster Grade Changes. EUR 5 Million Annual Value. No Equipment Upgrade Required.
The paper machine at a speciality paper factory performs up to seven grade changes per day, with some transitions taking as long as 90 minutes. These frequent and manual grade changes consume valuable production time, generating excessive waste and creating unnecessary process variability.
Anssum implemented an Advanced Grade Change Optimisation solution using the mill's existing control infrastructure. By automating and coordinating machine responses during grade transitions, grade-change duration was reduced by 40%, waste generation was significantly reduced and product quality consistency improved.
The solution unlocked EUR 5 million in annual business value through increased sellable production, lower waste, reduced operating costs and improved machine utilisation, all without the need for an equipment upgrade.
Complex Grade-Change Manufacturing Operation
A leading producer of speciality papers for demanding global applications, the paper machine produces predominantly greaseproof papers and related speciality grades.
The machine operates in a high-mix production environment requiring frequent grade changes to meet customer demand. These transitions occur multiple times per day and represent a significant operational challenge due to the associated production losses and waste generation.
Frequent Manual Grade Changes Limited Performance
The paper machine regularly performs multiple grade changes per day, with some transitions requiring up to 90 minutes to complete. During grade changes, operators manually adjust process parameters, monitor quality responses and coordinate machine operation to bring the process onto specification.
This resulted in:
· Excessive paper waste during transitions.
· Lost production time due to lengthy grade changes.
· Increased operator workload and intervention.
· Variable product quality during transition periods.
· Reduced machine utilisation.
· Inconsistent performance between operators and shifts.
Many grade changes are unique in nature, requiring operators to repeatedly determine the best transition strategy rather than relying on a consistent and repeatable operating procedure.
Automating and Standardising Grade Changes
Rather than recommending a capital-intensive upgrade, Anssum focused on extracting more value from the existing asset.
The solution included:
· Automated execution of grade-change sequences.
· Coordinated adjustment of machine setpoints during transitions.
· Advanced process control to manage interacting process variables.
· Automatic optimisation of machine responses throughout the grade change.
· Standardised operating logic to reduce variability between shifts and operators.
· Integration into existing control systems without requiring major hardware modifications.
The objective was to reduce transition duration, minimise waste generation and consistently achieve target product quality while maintaining operator ownership of the process.
Implementation Process
Step 1 – Understand the Process Constraint
· Analysis of historical machine performance and grade-change behaviour.
· Review of operating procedures, machine configuration and control strategies.
· Identification of representative successful and poor-performing grade changes.
· Quantification of production losses, waste generation and process variability associated with current operating practices.
This phase ensured the solution addressed the true operational constraint rather than symptoms of the problem.
Step 2 – Develop the Solution with the Mill Team
· Collaboration with production personnel, engineers and control specialists.
· Incorporation of operator knowledge and practical operating experience into the solution design.
· Evaluation of alternative grade-change strategies and their operational impact.
· Definition of operating limits, safeguards and performance targets.
The solution was developed collaboratively to maximise adoption and long-term sustainability.
Step 3 – Implement Within the Existing Control Environment
· Deployment of the optimisation strategy within the existing automation infrastructure.
· Automation of key operator actions and machine adjustments during grade changes.
· Coordination of process responses to reduce transition variability.
· Implementation without major hardware upgrades or disruption to existing operations.
Implementation was completed within systems already familiar to operators and maintenance personnel.
Step 4 – Commission and Optimise
· Commissioning of the solution alongside operations personnel.
· Optimisation of transition strategies across multiple grade combinations.
· Verification of waste reduction and grade-change performance improvements.
· Validation of stable and repeatable operation under production conditions.
Step 5 – Transfer Ownership
· Training of operators and technical personnel.
· Integration of the solution into normal operating practices.
· Establishment of performance monitoring and support processes.
Transfer of ownership enabling independent maintenance and continuous improvement by the mill team.
EUR 5 million in annual value
Anssum's solution successfully delivered the targeted reduction in grade-change duration while improving overall machine performance.
Key outcomes included:
· 40% reduction in grade-change duration.
· 25% reduction in transition waste.
· 52% increase in productive machine time.
· Improved machine utilisation.
· Improved quality consistency during grade changes.
· Reduced operator intervention requirements.
More repeatable and predictable machine performance.
Business Impact
· Increased saleable production through reduced transition time.
· Lower paper waste and associated manufacturing costs.
· Improved operational efficiency and asset utilisation.
· Reduced process variability and quality-related losses.
· Annual business value of EUR 5 million.
· No physical equipment upgrade required.
Most of the value was generated through additional sellable production made available by shorter and more efficient grade changes.
Key Takeaways
Frequent Grade Changes Hide Significant Value
Even relatively small reductions in transition duration can unlock substantial production capacity on a speciality paper machine operating multiple grade changes per day.
Production Time Is More Valuable Than Waste Reduction Alone
While waste reduction contributes meaningful savings, the largest source of value typically comes from increased productive machine time and additional saleable tonnes.
Automation Creates Consistency
Automated execution reduces variability between operators and shifts, resulting in more predictable performance and improved product quality.
Existing Assets Often Have Untapped Potential
Significant improvements can frequently be achieved through optimisation and control improvements without major mechanical modifications or capital projects.
Operator Involvement Drives Success
The most successful optimisation projects combine advanced technology with practical operating knowledge,ensuring both adoption and long-term sustainability.
Standardisation Improves Performance
Creating a repeatable and optimised grade-change process transforms a traditionally operator-dependent activity into a predictable and measurable production capability.
