EPIQ Boosts Mill Efficiency with Smart Upgrades

As a mill’s equipment ages, producers are still faced with the issue of improving operational efficiency and perhaps increasing output to compete with growing competition while keeping costs under control. Often, this could also mean a total mill conversion, for example, from newsprint to packaging grades. Or maybe just a change in roll width and/or diameter.

But, as technology evolves, how do mills integrate their legacy systems with this new automation technology?

The regional sales manager, northern U.S., for EPIQ Machinery, Andy Pienta, says the company saw an opportunity a few years back. At first, the focus was on the equipment from one of EPIQ’s predecessor companies, well known in the roll handling sector. Roll wrapping and ancillary equipment (winder decks) are still EPIQ’s forte.

However, its focus has widened, Pienta adds, as EPIQ realized it could help no matter what the customer’s legacy equipment brand. “We can go into a mill and do an assessment from a technical standpoint.”

Pienta says that as new technology evolved and markets change, mills are forced to “look inward” and be flexible. In other words, leaving their comfort zone. This could mean a new packaging process, increasing production or product conversion. “These are the main drivers for us.”

Often, a technological upgrade is needed. Some older systems are more than 30 years old. “We can breathe new life into the equipment,” he says.

Pienta adds that EPIQ itself has become more adaptable in solving issues. Not so long ago, old equipment had to be replaced. Now, EPIQ can install a new operating system that can extend the life of capital equipment, thus lowering capex.

One of the requests EPIQ deals with most often is for roll width increases. “Some mills have gone up to 132 in. from under 100 in.,” Pienta explains. Increasing capacity is another. “For each of these, we have solutions.”

Pienta cites one case of a converter that wanted to increase the size of the rolls it could handle. The challenge is that the roll wrapping process can be expensive, especially if roll throughput capacity is too low.

All went well with the project which took about a year to complete once the purchase order was received. There were some surprises along the way with some of the components of the aged machinery. “We set it up to be modular. There were a lot of manual interfaces before; operator training was required so they could handle the new system.”

Using some of the legacy equipment, EPIQ supplied a new dispenser and backstands, creating a hybrid system that included modern controls and safety features. The mill had an oversized crimping station that could be used integrated with the new equipment.

Source: EPIQ