Restoring Dryer Efficiency Through Mill Assessment

Restoring Dryer Efficiency: How a Comprehensive Dryer Assessment Improved Mill Performance

Challenge

A Midwest paper mill was struggling to reach its full efficiency potential. Persistent steam leaks and dryer flooding had led to valved-out dryers, steam loss, and wasted energy throughout the dryer section. Although the mill recognized these issues were reducing performance, it lacked the diagnostic insight to identify root causes or implement corrective actions. Seeking a trusted partner with deep steam system expertise, the mill turned to Kadant Johnson for a comprehensive evaluation and a sustainable solution.

Solution

Kadant Johnson responded by conducting a Comprehensive Dryer Assessment (CDA), a thorough inspection and evaluation of the paper mill’s dryer section. The assessment identified problem areas, documented their locations, and provided insight into potential causes of inefficiencies. Among the findings were rotary joints operating well beyond their expected lifespan, improper or missing anti-rotation rods, and corroded piping resulting from incorrect installation practices. After analyzing the entire dryer section, Kadant Johnson developed a clear corrective plan that prioritized system reliability and long-term performance. The recommendations included replacing outdated rotary joints, installing proper anti-rotation rod hardware, and addressing piping issues to restore efficient steam and condensate flow throughout the dryer section.

Results

Following Kadant Johnson’s detailed assessment and recommendations, the paper mill implemented the proposed upgrades, replacing worn repair parts, damaged anti-rotation rods and piping, and, where necessary, complete rotary joints. These improvements eliminated steam leaks, prevented future anti-rotation rod failures, and restored optimal system performance. As a result, the mill improved operational efficiency in the dryer section, energy use, reliability, and overall production consistency.

Highlights

Comprehensive Dryer Assessment (CDA) benefits:

Thorough inspection of accessible dryer section equipment
Identifies system bottlenecks and inefficiencies that reduce dryer performance
Detects steam and condensate losses to help lower energy consumption
Provides a detailed, documented report of problem areas, their locations, and root causes
Establishes a foundation for sustainable operations and continuous performance improvement