Paper Mill Cuts Sizing Costs by 12% While Improving Quality with eLIXA
Haber deployed its eLIXA® industrial AI platform to automate internal sizing control at a paper mill experiencing inconsistent Cobb values and high sizing chemical consumption. By combining real-time process monitoring, cloud-based analytics, and AI-driven dosing control, eLIXA stabilized product quality, reduced sizing costs, and minimized quality rejects.
The Challenge
Internal sizing is a critical papermaking process that improves paper resistance to water and other liquids by introducing hydrophobic sizing chemicals into the pulp stock. Maintaining consistent sizing performance is essential for achieving the desired Cobb values and ensuring reliable end-product quality.
The mill was experiencing:
- Inconsistent Cobb values
- High internal sizing chemical consumption
- Variable paper quality
- Increased quality rejects
- Customer complaints due to inconsistent product performance
Following a detailed technical assessment, Haber conducted a comprehensive process study and laboratory evaluation to identify the most suitable sizing chemistry and optimization strategy.
Haber's Approach
Haber evaluated the existing internal sizing program, process conditions, and laboratory data to identify the key factors affecting Cobb value stability and sizing efficiency.
Based on laboratory screening and process analysis, the optimal sizing chemistry and dosing strategy were selected to improve water resistance while reducing unnecessary chemical consumption.
eLIXA continuously monitored key process variables in real time and automatically controlled sizing chemical addition to maintain Cobb values within the target operating range.
Evidence-Backed Results
| Metric | Before | After | Change |
|---|---|---|---|
| Cobb value variation (SD) | 5.0 g/m² | 2.2 g/m² | 56% reduction |
| Internal sizing chemical consumption | 8.5 kg/t | 7.5 kg/t | 12% reduction |
Business Impact
By combining optimized chemistry with AI-driven process automation, eLIXA transformed internal sizing from a manually controlled operation into an intelligent closed-loop process.
Conclusion
Haber's eLIXA platform enabled the mill to achieve consistent internal sizing performance through real-time monitoring, AI-driven chemical dosing, and continuous process optimization. The deployment improved Cobb value stability, reduced chemical costs, and enhanced overall paper quality with minimal operational disruption.
