Case study
Installation of Automated Spray System Saves Materials Manufacturer Over US$1.4 Million a Year
Problem:
A prominent high-purity fiber producer needed to optimize the spray system used to manufacture fluff pulp. During processing, a surfactant mixture is applied to the fiber-based material used in diapers and personal hygiene products. The system oversaturated sections of the fluff pulp during start-up and slow-down and continued to spray during sheet breaks. These inefficiencies wasted costly surfactant, created a dangerous work environment and caused maintenance issues.
Solution:
The fiber producer now uses an AutoJet® PLC-based spray system. A spray header, equipped with eight PulsaJet® nozzles, applies the surfactant mixture to the top side of the fluff pulp rolls. The controller automatically adjusts the application rate with line speed increases or decreases to ensure the proper volume of surfactant is applied. The controller also turns the nozzles off when sheet breaks are detected.
Results:
The system, which includes four spray headers and treats two rolls simultaneously, has dramatically reduced operating costs and waste for the fiber producer. Surfactant use per roll has decreased by 15% since system installation. The savings on chemicals alone are US$1.4 million annually. In addition, the producer has reduced fluff pulp scrap due to over-saturation. The system cost was recouped in just two months.
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