Paper & Pulp Industry Automation
Paper manufacturing involves continuous processes, water treatment integration, and precise speed and tension control. Synergy Automatics delivers complete end-to-end automation for pulp and paper plants including dandy roll automation, pulp preparation, headbox control, paper machine drive synchronization, and winder/rewinder automation.
Our customized PLC, SCADA, and IIoT-based solutions improve sheet consistency, reduce energy and chemical usage, and increase overall mill throughput.
Automation Solutions for Textile Manufacturing
Pulp Processing Automation
- Refiners and pulper motor control
- Stock flow regulation with consistency transmitters
- Chemical dosing skid automation (alum, rosin, dyes)
- Deinking and screening system automation
- White water recovery monitoring
Paper Machine Automation
- Headbox pressure and flow control
- MD/CD moisture profiling automation
- Steam box and drying section PID loop tuning
- Vacuum pump and suction box sequencing
- Calendering section drive synchronization
Couch roll dewatering optimization
Drive & Motion Control
- Sectional drive control across forming, press, and drying
- Closed-loop speed synchronization
- Tension control using load cells and dancer rollers
- Reel diameter-based winder control logic
- Brake and clutch coordination for unwind stands
Rewinder & Winder Automation
- Reel changeover automation
- Slitting knife positioning control
- Auto tension adjustment based on roll diameter
- Accumulator speed profiling
- Core loading and finished roll unloading systems
SCADA & IIoT for Paper Plants
- Real-time production dashboards
- Moisture and basis weight trends
- Alarm & event logging by section
- Shift-wise machine uptime & stoppage analysis
- Integration with MES or ERP systems
Water Treatment & Utility Automation
- Effluent treatment plant (ETP) automation
- Clarifier and sludge dewatering control
- Water recycling and pH control
- Boiler and chiller plant integration
- SCADA-based flow and chemical tracking
Batch & Recipe Management
- Paper grade recipe management
- Centralized control for multiple product grades
- Operator interface for recipe editing and execution
- Alarm for grade change mismatch
Quality Inspection & Edge Control Systems
- Web edge detection and trimming automation
- GSM and moisture profile scanner integration
- Inline defect detection using vision systems
- Edge sensor calibration and alarm feedback
Retrofitting for Legacy Paper Machines
Supports old ABB/Bailey or standalone systems
Eliminates panel rewiring with plug-in modules
Integrates older drives with modern SCADA
SCADA/HMI conversion from InTouch to WinCC or FactoryTalk
Manual tension system → closed-loop automation
Drive replacement with VFDs for energy saving
Analog moisture profilers → digital SCADA integration
Benefits of Automation in Paper Industry
Improved reel quality with automatic tension management
Accurate dosing reduces chemical overuse and cost
Real-time alarms for vacuum pump or headbox failures
Improved operator productivity through HMI guidance
Reduced downtime through predictive maintenance
Centralized dashboard to monitor all processes
Enhanced compliance with environmental norms
Why Choose Synergy Automatics for Paper Industry Automation?
Proven expertise in automating paper mills across India
Experience with all major PLC, SCADA & drive brands: Siemens, ABB, Delta, Allen Bradley, Mitsubishi
On-site commissioning, AMC, and remote diagnostics
Compliance-ready solutions (ETP, safety interlocks, quality logging)
Deep knowledge of paper machine dynamics and reel handling
End-to-end solutions: design, panel building, PLC/HMI programming, installation
Custom SCADA dashboards tailored to paper machine zones
Seamless retrofit capabilities with minimal downtime
FAQ of Automation in Paper Industry
1. Can automation improve paper quality?
Yes — moisture, tension, headbox flow & drying control ensure uniformity and reduce defects.
2. Do you support retrofitting in old paper machines?
Absolutely. We upgrade legacy paper machines with PLC, HMI, and SCADA for improved reliability.
3. What is MD/CD moisture profiling?
It refers to controlling moisture across Machine Direction (MD) and Cross Direction (CD) to ensure paper uniformity.
4. Can we automate slitting and rewinding?
Yes — we offer PLC-based rewinder automation with automatic tension, knife positioning, and reel unloading.
5. Is it possible to monitor chemical dosing remotely?
Yes — through SCADA/IIoT, you can track chemical dosing volumes and trends in real time.
6. Do you offer AMC and training?
Yes — we offer annual maintenance, operator training, and remote diagnostics support.
7. Do you support GSM and moisture control integration?
Yes — we integrate online sensors and provide closed-loop GSM/moisture regulation.
8. What safety systems do you implement?
We offer motor overload protection, E-stop interlocks, and SCADA alerts for pressure/temp deviations.
9. How is tension control implemented?
Using load cells, VFD control, and sectional drive synchronization logic.
10. Can reports be accessed remotely?
Yes — via cloud dashboards or mobile alerts for managers and technicians.