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Honeywell Helps Carvajal Pulp and Paper Drive Smart Operations

Carvajal Pulp and Paper was challenged to lower its Manufacturing Costs to become more competitive. This reflected in the needs to gain more control over energy costs, chemical costs, and production losses.

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  • SUPPLIER
  • Honeywell
    Honeywell invents and manufactures technologies to address some of the world’s toughest challenges initiated by revolutionary macrotrends in science, technology and society. They improves business performance for customers with automation and control solutions, equipment and services that enhance safety, reliability and efficiency. Year founded: 1906 Revenue: $40.3 billion (2014) NYSE: HON
  • INDUSTRIES
  • Chemicals
  • FUNCTIONS
  • Product Development
  • CUSTOMER
  • Carvajal Pulp and Paper (formerly Propal) is part of the Carvajal S.A. Group, a privately owned company established in 1904 and headquartered in Cali, Colombia, with over 20,000 employees and annual revenues of over US$ 1.7 billion from seven sectors and operations in 16 countries.

  • CONNECTIVITY PROTOCOLS
  • SOLUTION
  • Carvajal Pulp and Paper engaged with Honeywell's consultants to work on the company's challenges and needs; Honeywell began engineering a flexible, vendor-independent solution to integrate Carvajal Pulp and Paper's plant floors with its entire enterprise. Honeywell presented a comprehensive solution to achieve Carvajal Pulp and Paper's vision of Smart Operations.

    The solution makes the best use of the company's process and information technology investments. It complemented existing systems such as ABB Distributed Control System (DCS) and Quality Control System (QCS), Honeywell OptiVision (MES) and SAP (ERP).

  • DATA COLLECTED
  • Energy Cost Per Unit, Machine Performance, Speed, Temperature, Throughput Per Plant
  • SOLUTION TYPE
  • SOLUTION MATURITY
  • Mature (technology has been on the market for > 5 years)
  • OPERATIONAL IMPACT
  • Impact #1

    A detection of large steam temperature fluctuations on a paper machine's drying section, which affected product quality over an extended period.

    Impact #2
    [Efficiency Improvement - Issue Response]
    Immediate resolution of frequent variations of amperage and speed in the press section.
    Impact #3
  • QUANTITATIVE BENEFIT
  • Benefit #1

    25% - 30% downtime reduction on paper machines.

    Benefit #2

    3% reduction in rejects per run.

  • USE CASES
  • Factory Operations Visibility & Intelligence
    Visualizing factory operations data is a challenge for many manufacturers today. One of the IIoT initiatives some manufacturers are pursuing today is providing real-time visibility in factory operations and the health of machines. The goal is to improve manufacturing efficiency. The challenge is in combining and correlating diverse data sources that greatly vary in nature, origin, and life cycle. Factory Operations Visibility and Intelligence (FOVI) is designed to collect sensor data generated on the factory floor, production-equipment logs, production plans and statistics, operator information, and to integrate all this and other related information in the cloud. In this way, it can be used to bring visibility to production facilities, analyze and predict outcomes, and support better decisions for improvements.
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