In 2016, Brazil’s largest producer and exporter of pulp and paper, Klabin, was hard at work constructing its Puma plant – a factory in the city of Ortigueira that was expected to produce 1.5 million tons of short and long fiber pulp each year.
To maximize plant efficiency, Klabin sought a solution that would optimize data collection and analysis, theorizing that simpler, more accessible data insights would lead to faster, more informed business decisions. After vetting several potential partners, Stefanini Group was selected to implement a Plant Information Management System (PIMS) for the Puma plant.
COMPANY INFORMATION
- Founded: 1989
- Employees: 25,000
- Industry: Manuacturing
Situation:
Klabin is largest producer and exporter of pulp and paper in Brazil. As a leader in the corrugated paper market, Klabin offers packaging solutions in hardwood, softwood, and fluff pulp, operating more than 20 mills across the country. The company, which has been recognized for its sustainable performance by the Dow Jones Sustainability Index (DJSI), also holds the title of the largest paper recycler in Brazil
Challenge:
In 2016, Klabin was hard at work constructing its Puma plant – a factory in the city of Ortigueira that was expected to produce 1.5 million tons of short and long fiber pulp each year, in addition to generating 270 megawatts of energy and selling 150 megawatts of surplus energy.
To maximize plant effciency, the company sought a solution that would optimize data collection and analysis in the hopes that it would lead to faster, more informed business decision making.
After careful consideration, Stefanini Group was selected to implement a Plant Information Management System (PIMS) for the Puma plant with the goal of integrating information from the client’s many systems, centralizing available data and promoting efficient access to it.
Solution:
To understand Klabin’s business processes, Stefanini worked with OSIsoft’s IP platform to collect, organize and transform data into information. The PIMS solution developed for Klabin features 75,000 tags on instruments, control valves, electric motors and pumps, allowing the company to track and trace the variable dynamics of these elements.
These systems were integrated through a PI system, but in partnership with Klabin, Stefanini also developed several tools to add value to the raw data collected. For example, the traceability tool allows users to track products at any stage of the production process, and the decision-making aid helps floor coordinators set production paces.
Results:
The results of the system implemented by Stefanini were significant, making the entire management ecosystem for this type of industry more effective, interactive, and user-friendly – with meetings, mandatory stops, balance sheets, production rhythms, and decisions on costs and consumption now being based on real-time data.
$10 Mil saved in maintenance costs
Increased the plant’s production by 3,400 Tons
These tools allow us to monitor and manage them, even from a distance, with gains in reliability, quality and production increments, which are so fundamental to our results,“
“The direct participation of our automation team, integrated with the [Stefanini] teams, was essential for the success of this project.”
adds Francisco Razzolini, Director of Industrial Technology, Innovation, Sustainability and Projects at Klabin.
