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Legacy systems and manual workflows drive hidden losses and variability, resulting in a multitude of hidden leaks that result in millions of dollars of lost savings opportunities
Tracking and managing energy losses remains a challenge due to hidden inefficiencies and disconnected systems like these:
High-pressure steam losses in digesters or dryers
Unseen compressor and chiller inefficiencies
Manual logs or a siloed SCADA for utility data
No visibility into resin or thermal energy metrics
Without proactive systems in place, downtime often strikes unexpectedly - here’s how it shows up on the ground:
Equipment failures in winders, cutters, or refiners
No predictive alerts for rotating or thermal assets
No predictive alerts for rotating or thermal assets
Operators rely on experience, not diagnostics
Lack of real-time insights leads to inefficiencies and blind spots across production cycles, such as:
No OEE visibility across pressing, coating, and converting
Missed opportunities during order changeovers
Quality deviations are detected too late in the process
Line output losses not tied to batch or shift
Critical safety lapses often go unnoticed due to missing logs and delayed responses - here are some real-world examples:
Thickness, moisture, or surface issues caught post-run
Print or lamination defects missed at high speed
No traceability of issues to resin, glue, or machine
Lack of inline QA checkpoints or vision systems
Inefficient systems and scattered data often stall compliance efforts - manifesting through issues like these:
Emissions, effluent, or energy data captured manually
Incomplete tracking of raw material usage and waste
Safety and EPR reporting delays due to paperwork
Missing audit trails for water, air, or fire systems
Unlock peak plant performance across energy, reliability, productivity, safety, and compliance for every stage of chemical manufacturing, driving efficiency and measurable results.
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Digital transformation enables US mills to unlock measurable, department-wide value
Our full-stack platform drives ground-up digital transformation, deploying from field devices to enterprise systems. Each product module works in seamless succession to unify, analyze, and optimize every layer of chemical manufacturing.
The industry spans diverse operations, right from round-the-clock pulp mills to precision-driven packaging lines and engineered wood production.
September 11, 2025
2min read
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September 11, 2025
2min read
September 11, 2025
1min read
