The plant was operating at a high specific steam consumption (SSC) of 2.2 Kg/Kg (4.4-4.8 Pounds/Pounds) of paper, significantly above the desired target of 1.9 Kg/Kg (4.1 Pounds/Pounds), resulting in excess steam usage and higher energy costs.

Detailed benchmarking of specific steam consumption (SSC) and condensate recovery factor (CRF) through plant survey and site assessments.

Reduction of medium pressure steam usage in coaters by:

• Improving trap uptime for all coater heaters
• Using medium pressure condensate flash in low pressure dryer groups
• Installing an On/Off control system to cut steam during paper breaks

Conversion of MG dryer TC (mechanical glazing dryer thermocompressor) system from motive steam-based to cascade-based operation, reducing medium pressure steam usage.

Changing of 25 Tonnes Per Day (55K Pounds Per Day) medium pressure steam by converting it into low pressure steam, enhancing turbine house power generation.

Continuous digital monitoring and proactive maintenance of control system uptime, including pressure loops, differential pressure control loops, level control loops, and other instrumentation.

Preparation of GSM-wise and speed-wise recipes for optimised pressure and differential pressure control loops settings to ensure lower energy consumption and improved production quality.

Reduced specific steam consumption (SSC) from 2.1-2.2 Kg/Kg to 1.76 Kg/Kg.

Improved condensate recovery factor (CRF) from 81% to 85-88%.

Paper production improved from 205 TPD to 225 TPD.

Reduction in paper break ratio (numbers/day) from 0.5 to 0.2-0.3 to optimise the steam consumption during break.

Reducing medium pressure steam consumption in coaters from 95 TPD to 50-55 TPD, improving energy efficiency and reducing operational costs.

Fine Tuning the PID values for each control loop to achieve the set point by taking the system online.