Predicting and Avoiding Wet-End Paper Breaks and Other Process Event
Join us for an in-depth webinar demonstrating how PPCL’s CPM multivariable modeling technology is being successfully applied in Pulp Mills and Stock Preparation processes to reduce costly paper breaks and improve production stability.
Paper breaks—especially at the Wet End of the paper machine—are a major cause of downtime and lost production. Just one break per day, with an hour of cleanup and restart, can result in up to 4% production loss. These events often stem from unmeasured process variations—such as pulp composition changes from recycled materials—that current control systems can’t predict or respond to.
In this session, you will learn:
• How multivariable geometric modeling (a unique form of machine learning without equations) can detect subtle process changes that often lead to breaks.
• Why ‘broke’ paper reprocessing introduces additional variability and instability in stock preparation.
• How Operating Envelope models provide real-time guidance to Wet-End operators, helping to adjust machine settings in response to unexpected pulp properties.
• How CPM models are applied in batch, multi-grade, and multi-mode processes, with automatic real-time switching between modes or grades.
• Why PPCL’s GPC and CPM solutions require only standard Windows PCs—no specialized hardware or complex infrastructure.
We’ll also draw comparisons with other applications of this technology in industries like gas processing, where sudden feed changes can have similar impacts—demonstrating the broad applicability of this predictive, real-time modeling approach.
Who should attend?
• Paper Mill Process Engineers and Operators
• Control and Automation Engineers
• Production Managers
• Anyone involved in optimizing wet end performance or reducing unscheduled downtime
Are Alarms no worse than anyone else's the height of your ambition? (delivered in Hindi)
For decades, plants have struggled with ineffective operator alarms—often relying on outdated univariate methods and compromise-driven rationalisation. But what if you could see your normal operating zone—and set alarm limits with confidence, accuracy, and trust?
Join us for this powerful session where you’ll discover how to use multivariable analysis to define your plant’s true operating envelope—visually, clearly, and without any complex math. This technique allows you to set alarm limits that actually reflect how your process operates and where your alarms should be.
What You’ll Learn:
• Why traditional alarm rationalisation methods fail—and how to fix it
• How to define your true operating window using all relevant plant data
• How to set alarm limits that reduce nuisance alarms, provide earlier warnings, and restore trust in the alarm system
• A real-world success story: how one site solved alarm flooding and boosted performance company-wide
Are Alarms no worse than anyone else's the height of your ambition?
For decades, plants have struggled with ineffective operator alarms—often relying on outdated univariate methods and compromise-driven rationalisation. But what if you could see your normal operating zone—and set alarm limits with confidence, accuracy, and trust?
Join us for this powerful session where you’ll discover how to use multivariable analysis to define your plant’s true operating envelope—visually, clearly, and without any complex math. This technique allows you to set alarm limits that actually reflect how your process operates and where your alarms should be.
What You’ll Learn:
• Why traditional alarm rationalisation methods fail—and how to fix it
• How to define your true operating window using all relevant plant data
• How to set alarm limits that reduce nuisance alarms, provide earlier warnings, and restore trust in the alarm system
• A real-world success story: how one site solved alarm flooding and boosted performance company-wide
How to Reduce Process Energy Usage- Delivered in Hindi
Record high energy prices put a focus on reducing your plant energy expenditure. How can this be done quickly without expensive modelling or data collection?
In this webinar we show you how to find operational changes to minimize your energy usage using only data already present in your plant historian. Implementing these findings with operations quickly can then have immediate and significant cost savings.
How to Reduce Process Energy Usage
Record high energy prices put a focus on reducing your plant energy expenditure. How can this be done quickly without expensive modelling or data collection?
In this webinar we show you how to find operational changes to minimize your energy usage using only data already present in your plant historian. Implementing these findings with operations quickly can then have immediate and significant cost savings.
Understanding, Managing and Eliminating Alarm Floods
One of our customers came to us after multiple failed attempts to fix severe Alarm Floods in his steam plant. Operators had stopped relying on the alarms entirely — a dangerous situation.We helped him quickly reset his Operator Alarms using a smarter, multi-variable approach. The result? Operating problems dropped, performance KPIs soared, and Head Office took notice. Join our webinar to see how you can do the same — faster and with lower project costs than traditional methods.
Consistent Alarms Improve Bottom Lines through Improved Process Operations
Tell a process operator whether he is inside or outside the desired operating envelope and he will be able to operate better. Show him and he will operate better still. You will see the benefits of better operation in your plants bottom line.
For basic level applications good, tight operator alarms give the operator the ability to steer the process in a multi-variable environment that he lacks today. The GPC method of finding consistent multi-variable Operator Alarm Limits is science-based so alarm limits can be much tighter because they are consistent with the Operating Envelope and so with each other so delivering much lower alarm rates and giving the operator earlier indication of developing problems hence more time to think about and understand what process alarms are really telling him about his operation.
Beyond SPC: Enhanced Process Monitoring with Geometric Process Control (GPC)
Statistical Process Control (SPC) has struggled to deliver the same value to process industries as it has to manufacturing. This comes down to the statistical nature of the tools. Geometric Process Control (GPC) provides the necessary tools to realize these benefits in the process industries.
Detect Abnormal Events Early and Keep Your Process Running with Geometric Process Control
Imagine having 10 minutes or more warning of upcoming abnormal events such as compressor surge or turbine trips, and days warning of slowly developing equipment faults. Operators would have the time to adjust the process to avoid or minimize the impact of the events! This month’s webinar shows how you can build a model from process history and existing engineering knowledge in hours or days.
Better Operating Targets and Alarms for Multi-mode and Multi-Grade Processes: Improve Quality and Reduce Waste
Most of the examples we use in our webinars are single-mode continuous processes, but no process is that simple. There are separate operating modes for startup, shutdown, catalyst regeneration, reduced rate running, grade transitions, as well as alternate equipment configurations. For batch processes a product recipe defines the start and end-conditions of phases. These phases map onto modes in Geometric Process Control (GPC). There are benefits in extending process knowledge by exploring, visualizing, and modeling the operating envelopes of modes (or phases) visually, individually as well as in aggregate, to discover variable and quality interactions.
Minimize Greenhouse Gas Emissions and Energy Use with GPC
We have invented an easy-to-use entirely visual method based on geometry rather than algebra needing very little user mathematics that can pluck the correct values out of the large amounts of data held in your process history database in a few minutes. It will give you the correct values and calculate how many dollars you can save. Come and see for yourself!
Predictive Maintenance with Operating Envelope Models
This webinar focuses on Geometric Process Control and Envelope-based models, showing how using only historic data a model of normal operation can be built that alerts when the process relationships have changed outside their normal range, providing warning of potential upcoming faults and triggering maintenance. The sensitivity of these models delivers much earlier warning and allows more time to schedule predictive maintenance. The low-cost, low-time delivery of GPC models is ideal for bringing predictive maintenance to smaller pieces of equipment that we now have data for.
A Digital Twin For Process Operations Based on Best Operation
Imagine your process performance if every operator had the insight of your most experienced expert operators. Now you can with Digital Twin models encapsulating the accumulated knowledge of your best process operation. With this continuous help process operation will improve, reducing operating costs, emissions and energy usage and delivering higher yields, more consistent product and a safer process. This technology is applicable to single and multi-mode continuous processes, batch and multi-grade processes including grade transitions. It is easy for your engineers to implement.
Delivering Operational Excellence
In this webinar we will demonstrate how operating envelopes can be used to achieve your KPIs in an Operational Excellence (OpEx) framework. We’ll show how anyone can see a full feed-to-product operating envelope, evaluate KPI targets with baseline performance, identify and resolve inconsistent KPIs, and find appropriate leading KPIs. This dramatically reduces time and builds confidence in the process, increasing acceptance and showing exactly how to operate to achieve goals.
Do not use the Bad Actor Method for Adjusting Alarm or Operating Limits
You’ve rationalized your Alarm and Operating Limits with CVE and are getting the best alarm performance you have ever had. Why would you want to adjust limits and how should you do it? The Capability of many processes changes over time. Eventually you will start getting alarms on temperatures and flows and usually for more than one variable. These are the Bad Actors you want to adjust. You have to do it multi-variably not one at a time but it is quite easy with CVE and we will demonstrate how to do it in this webinar.
What's New in CVE 2.8.2
C Visual Explorer (CVE) is PPCL’s flagship product that enables visualization of thousands of variables and hundreds of thousands of operating points. Powerful data interrogation tools allow filtering and analysis of the data purely visually without require training in statistics or other higher mathematics.
This webinar shows what is coming in CVE 2.8.2, including query outlines, text substitution, selectable color palettes, exporting Pareto information, tools for C Process Modeller (CPM) output, UNICODE support, and numberous bugfixes and enhancements.
We show the new features in the context of process questions and general investigation techniques, no prior knowledge of CVE is required.
Real-Time Operating Envelope Applications: Basics to Cutting-Edge
Geometric Process Control (GPC) helps users understand, improve, and operate their processes.
This webinar focuses on interpreting the full operating envelope, starting from offline response surface applications and moving through typical process optimization, event prediction and digital twin operations to transient, multi-modal models and finally look at some current developments and their promise for the future. Demonstrations with C Process Modeler (CPM), our real-time product, are included.
Operational Process Improvement: You already have the Data
You already have the data for enormous potential in improving plant operation through making operational changes to capture, repeat, and improve best historic operation. Understanding your process behavior is key to unlocking benefits such as higher throughput, better product, lowest costs, less waste, and more uptime.
