Valmet has introduced its IQ Virtual Sensor, a software-based solution said to enable paper and board mills to maintain consistent quality, reduce fibre and starch costs, decrease energy consumption and increase overall production efficiency.
By providing continuous quality predictions, the new solution is designed to give producers real-time visibility of critical end-product strength properties traditionally measured in the laboratory. Valmet says the system delivers minute-by-minute predictions of key paper properties such as tensile and tear strength, burst and short-span compression test (SCT), using the mill’s existing data.
Apparently, all calculations on Valmet’s IQ Virtual Sensor run locally without cloud dependency, ensuring secure data handling and fast response times. Integrated with Valmet DNA and Valmet DNAe, the solution allows operators to view predicted strength properties alongside other quality data from scanners.
Available as a standalone solution, the Sensor can be combined with the Valmet IQ Quality Control System (QCS), providing mills with a holistic quality overview across the entire machine and tighter control of essential quality parameters in one unified interface. Almet adds that the solution can be expanded to automated closed-loop controls with Valmet Advanced Process Controls (APC).
“With Valmet IQ Virtual Sensor, operators no longer need to wait for laboratory results to understand how their actions will affect end-product quality. Its built-in “what if” simulator lets operators test adjustments and see predicted impacts before applying changes to real production. By reducing uncertainty and enabling lower safety margins, the solution demonstrates how optimized process control helps unlock resource efficiency,” says Timo Aro, business manager of Quality Management Systems and Automation Solutions at Valmet.
At the end of 2025 Valmet revealed its Wet End Analyzer, designed to help paper, board, and tissue producers improve wet end processes to achieve improved product quality, process stability and reduced operating costs. The new analyzer supports continuous online sampling of total fibre and fines consistency and ash consistency from up to three lines.
In related news, flow-control technology company John Crane (a Smiths business) recently claimed it helped a US pulp and paper mill reduce water consumption by 90% and save $75,000 in total cost of ownership through a mechanical seal upgrade in its cellulose fibre production process. By deploying its Type SB2 USP heavy-duty dual cartridge mechanical seal with Upstream Pumping (USP) seal face technology, the mill was able to extend seal life from weeks to over than a year while ‘sharply reducing’ water demand.
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