PROCEDURE FOR MODELING CORRUGATED PAPER PRODUCTION PROCESSES FROM FACTORY CONTROL DATA

Abstract

Introduction:
The paper industry faces challenges of efficiency, quality, and cost, exacerbated by changes in raw materials and technologies. In Cuba, plants with outdated technologies require maximizing productivity through scientific methods.
Objective:
To establish a procedure for the mathematical modeling and techno-economic optimization of industrial paper manufacturing processes, applicable to different facilities and products.
Materials and Methods:
A global process decomposed into stages and elements is proposed. Each stage is modeled using multiple regression or mixture models (Scheffé) with industrial data through experimental designs. Optimization is carried out in two levels: operating variables were optimized using the Simplex method, and the mixture proportion was optimized using the Fibonacci technique. Fisher's F-test is used for all stages, and a global optimization for fresh and stored bagasse is performed, with statistical validation of the model based on analysis of variance (ANOVA).
Results and Discussion:
A procedure is obtained that allows simulating the effect of operational changes on quality and cost. The two-level optimization demonstrated that it is feasible and economically advantageous to operate with a mixture containing up to 65% recycled paper pulp and 35% virgin bagasse pulp, surpassing previous empirical limits.
Conclusions:
Stage‑wise synthesis and matrix aggregation facilitate obtaining a global model of the process. Two‑level optimization provides a practical decision‑making tool, improving efficiency in paper mills with limited resources.