Simulating pulp grades for higher quality and cost-efficient end products
Pulp is a versatile material suitable for various end-use applications, with its technical properties influenced by the wood species, growth conditions, and production process. The characteristics of the pulp used as a raw material significantly affect the quality of the final product. Metsä Fibre’s technical experts offer deep fibre knowledge to help customers optimise their furnish recipes and select the most suitable pulp for each application – whether it’s tissue paper, packaging board, or printing products.
One of the key tools in Metsä Fibre’s technical customer service is the simulation program FIT (Furnish Improvement Tool), which allows comparison of different pulp grades and simulation of their impact on the customer’s end product. The tool is based on over 20 years of data collected from various market pulps and can be widely applied in assignments such as new product development.
Simulation also helps identify optimal pulp choices when customers aim for cost-efficiency without compromising product performance. The technical properties of Metsä Fibre’s softwood pulp can enable recipe changes that reduce overall costs. Nickull explains:
“The unique technical properties of high-quality northern softwood pulp, together with our expert technical customer service, enable the optimisation of the proportion of softwood pulp in the paper structure without sacrificing end-product quality. As a result, the customer has achieved a more cost-effective solution and reduced overall production costs.”
Field services at the heart of production
In addition to the selected pulp grade, how the pulp is processed in the customer’s production line significantly affects the end-product properties. Proper refining can fine-tune the fibre structure, enhancing strength and printability without sacrificing dewatering. Therefore, refining optimisation plays a central role in ensuring overall production quality.
Metsä Fibre’s field services bring expert knowledge directly to the customer’s production site. As part of this service, a technical expert visits the customer’s facility to familiarise themselves with the process conditions and equipment on-site. When needed, samples from the pulp refiners are taken for analysis, and solutions for process improvement are sought in close collaboration with the customer.
Alongside on-site observation, Metsä Fibre uses the analysis tool FORE (Furnish Optimization and Refining Evaluation), which enables data-based examination of the customer’s production process, especially pulp refining. By collecting information on equipment and process conditions, FORE can simulate the impact of refining on product properties and process efficiency.
“With FORE, we can detect, for example, if refining consistency is too low, fillings are worn, or energy is being wasted with oversized motors. The tool helps us support our customers in optimising their processes, improving product quality, and reducing costs”, Nickull describes.
Refining evaluations ensure that the pulp’s full potential is utilised as efficiently as possible in the customer’s production. Optimised refining not only improves product quality but also affects energy efficiency and raw material costs. Many challenges in the refining process can be prevented through early collaboration.
“We’re happy to be involved in our customer’s project already in the planning phase, supporting the selection of the right equipment solutions and ensuring the process supports the customer’s goals from the very beginning”, Nickull summarises.
Concrete savings and continuous development
Technical value-added services aim for measurable results.
“We’ve conducted nearly 200 refining evaluations, and based on our experience, there’s almost always room for improvement – sometimes it’s minor adjustments, other times broader development projects”, Nickull says.
It’s estimated that refining evaluations can yield savings of 1–5 euros per tonne of produced paper, which at high volumes can mean annual cost savings of hundreds of thousands of euros.
“In the face of global cost pressures, our role is to help our customers find savings through better fibre recipes and more efficient fibre processing. The best feedback, of course, is when the customer wants to do more joint projects”, Nickull concludes.