Solving equipment failure with ceramic dewatering upgrades - Paper mill wet-end optimization

A large paper mill in the U.S. South faced an urgent reliability challenge in its wet-end operations due to aging and obsolete equipment. By implementing a redesigned ceramic solution, the mill improved equipment performance, reduced maintenance costs, and set the stage for long-term operational reliability.

This case study highlights how modern dewatering technology and rapid engineering support can help paper mills overcome critical equipment failures without disrupting production schedules.

Customer challenge: Aging, obsolete equipment threatens production

In high-speed paper manufacturing, wet-end reliability is essential to maintaining uptime and product quality. At this mill, the secondary landing box cover had been in service for over 20 years and showed significant signs of wear and structural damage.

Key challenges included:

• Obsolete design with no available spare part
• Visible wear and damage impacting performance
• Risk of unplanned downtime during operation
• No backup cover, increasing operational vulnerability
• Pressure for rapid turnaround without disrupting outage schedules

With production continuity at stake, the mill required a solution that could be engineered, manufactured, and installed quickly—without compromising performance.

Solution: Engineered ceramic redesign with rapid delivery

A new secondary landing box cover was engineered to modern specifications and manufactured domestically to enable faster delivery.

The upgraded design incorporated advanced ceramic and structural improvements to optimize performance and durability:

Key design enhancements

• High-performance ceramic materials
  Premium aluminum oxide ceramics were used to improve wear resistance and extend component life.
• Slotted cover design
  Maintained the same open area as the previous design while improving drainage efficiency.
• Replaceable ceramic rails
  Enabled cost-effective maintenance by allowing individual components to be replaced instead of the entire cover.
• Chamfered rail geometry
  Reduced drag on the forming wire, helping to:
• Minimize wire wear
• Lower drive loads
• Improve energy efficiency
• Optimized structural design
  Stainless steel cross members with pointed tops prevented fiber buildup and plugging, improving cleanliness and operational stability.

Execution excellence

• A Potential Problem Analysis (PPA) was conducted before installation to mitigate risks
• Installation was coordinated with existing outage schedules, avoiding production delays
• Manufacturing and delivery were expedited to meet urgent timelines

Results: Improved reliability, lower costs, and future opportunities

The project delivered immediate and long-term benefits for the mill:

Operational improvements

• Restored reliability of the secondary landing box
• Reduced risk of unexpected downtime
• Improved drainage and wet-end efficiency

Maintenance & cost benefits

• Lower maintenance costs through replaceable components
• Reduced wire wear and extended equipment life
• Improved cleanliness, reducing manual intervention

Why ceramic upgrades matter in modern paper mills

As paper machines age, legacy components often become bottlenecks to performance. Upgrading to modern ceramic solutions offers several strategic advantages:

• Extended equipment lifespan
• Reduced total cost of ownership
• Improved energy efficiency
• Enhanced process stability
• Future-ready modular maintenance

A scalable model for wet-end optimization

This project demonstrates how a targeted equipment upgrade—executed with speed and engineering precision—can deliver significant operational gains.

For paper mills across North America, particularly in the U.S. South where aging assets are common, ceramic dewatering upgrades represent a practical and scalable path to:

• Improve reliability
• Reduce operating costs
• Unlock additional optimization opportunities