Customer Case: From Nozzles to Net Savings – Real World Paper Machine Optimization Without Capital Expenditure

In this recent customer case, Fiber-X supported a full scale paper mill in achieving significant process improvements with minimal investment. Through detailed auditing and expert analysis, the mill reduced water consumption by over 25 m³/h, all without expensive equipment upgrades. Paper Machine Optimization is one of our core elements and services.

Our approach challenged every drop of water used in the process: Is this water truly necessary? Can it be reduced, replaced with filtrate or recycled?

In the world of paper production, small operational adjustments can often unlock major efficiency gains

Key results included:

Shower nozzle optimization: Nozzles on high and low pressure showers were resized to better match process needs. This reduced excess flow and saved water without affecting performance.

Sealing water circulation retrofit: Vacuum pump systems were modified to reuse sealing water, turning what was previously waste into a resource.

Fiber loss identification: Discharge flows and filtrates were analyzed to uncover hidden fiber losses and opportunities for recovery and cost savings.

The improvements required no new major equipment. All changes were implemented using the customer's existing infrastructure and several suggestions were applied immediately during normal operations.

Why choose Fiber-X for Paper Machine Optimization

We offer a neutral and experienced partner for pulp and paper producers. Our team consists of seasoned engineers with backgrounds at Valmet, Voith and Andritz. They bring extensive knowledge across different machine types and technologies.

We have seen that most process inefficiencies can be identified remotely with process diagrams and field photos. In many cases on site visits are not even required.

If your site is facing energy or water challenges or wants to improve output with minimal risk, our audit and optimization service can help.

Contact us and let’s find out how to reduce waste and improve performance together.