Vigilance™4.0: Yankee Performance Monitoring

All your crepe process and Yankee performance data in the same place, in real time, giving you the power to drive performance.

Monitoring crepe blade vibration is an accepted tissue industry practice for improving Yankee operations performance, but diagnosing the root causes of issues in your process is time consuming and needs expert insight. With BTG’s Vigilance 4.0, all the relevant crepe process troubleshooting data is in the same place, in real time, offering the process engineer significant opportunities to enhance quality, productivity and asset protection.

BTG’s new Vigilance™ 4.0 combines our years of crepe blade vibration monitoring experience and our extensive tissue process know-how with Capstone’s dataPARC, an industry leading data analytics platform.

Vigilance 4.0 delivers economic impact

Based on conservative estimates of cost savings or productivity gains from recent BTG case histories, a Vigilance 4.0 system, correctly used, could easily yield a payback time of just a few months.

Diagnosis of the root causes of high vibration, poor quality or reduced production rate can be complex and time consuming, and yet very often the issue needs to be addressed immediately to prevent lost profit opportunity or Yankee damage. Vigilance 4.0 embodying expert unit-operations know-how to assist operators and process engineers in diagnosis of quality, productivity or vibration issues as they relate to the Yankee. The modules, and the impact they can enable, are as follows:

Wet-End Chemistry and Coating

Hard coating, wrong add-on, streaky coating, incorrect release ratio: these issues can bring about a multitude of quality and productivity issues, including loss of softness, low bulk poor crepe ratio, edge tears and web breaks as well as impacting crepe blade vibration. The wet-end dashboard tracks these calculated key performance indicators (KPI’s) include among other possibilities:

  • Coating ratio
  • Crepe efficiency
  • Coating contamination factor
  • Spraybar configuration

The economic impact can be in improvements in quality or productivity as well as reduced vibration. For example, we know that Yankee coating density can affect bulk, ability to reduce crepe ratio and vibration. Coating density in turn is influenced by add-on ratios, wet end pH, spraybar configuration and wet end contamination, which are all calculated and tracked in this module. For example, each 1% of sustainable crepe ratio reduction on a 3 m trim machine can represent €115,000 profit opportunity. Vigilance 4.0 can display the critical calculated centerlines for achieving this.

Steam and Condensate

The steam and condensate operational efficiency is very influential on a tissue machines cost, productivity and asset safety performance. For example, incorrect blowthrough/condensate ratio can lead to flooding or partial flooding conditions, especially on a new felt or on start –up. The so-called ‘J curve’ or system resistance curve can be calculated and displayed by Vigilance, and the low point of this curve defines the most efficient use of steam. Once calibrated by BTG experts, it gives the operators a new KPI for energy consumption. For example, in once recent case, motive steam flow was reduced by 5% with no loss in drying efficiency. Based upon average steam costs, that represents €52,000 per year energy savings.

Vibration Monitoring

Vibration monitoring is now an inherent and accepted methodology for determining the correct coating density for quality and productivity. But if we look at its original purpose, alarming against high crepe blade vibration, we can define the cost savings for prevention of Yankee damage. This might mean setting alarms to prompt a change in operations, such as coating adjustment crepe or cleaning blade change to mitigate high vibration. The new Vigilance™ 4.0 vibration dashboard makes this easier than ever with the automatic tracking and comparison of blade by blade performance. Suppose, for a troublesome machine, the regrind interval was extended from 12 to 24 months; between regrind and lost production costs, this equates to a €50,000 per year cost saving.

For more information on Vigilance™ 4.0, please contact our experts at