Web breaks shut down production for hours. Press section failures degrade sheet quality. Dryer section upsets cause cascading grade changes. ProcessIQ gives your engineers AI-powered root cause analysis across every machine zone — on demand, any shift.
ProcessIQ covers every major section of a paper machine — from stock prep through the reel. Each area is loaded with paper-specific failure modes, basis weight and moisture interactions, and cross-direction profile considerations.
A single web break costs 15–90 minutes of production time plus cleanup and restart. ProcessIQ helps your team work backwards from the break point to find the upstream cause — not just treat the symptom.
Paper mills have some of the highest downtime costs in manufacturing — averaging $18,000 per hour for unplanned stoppages. At that rate, a 30-minute diagnostic delay without ProcessIQ costs $9,000 per incident.
At $18,000/hour downtime cost, one prevented incident covers your annual ProcessIQ subscription — with over $3M in projected annual savings based on improved break frequency and faster recovery time.
The zone where a web break occurs is typically 1–3 zones upstream from where the defect originated. ProcessIQ's structured diagnostic approach traces the signal backwards to find where the real problem started.
Industry data shows that 80% of repeat break events are caused by recurring conditions — felt condition, headbox consistency drift, dryer can buildup — not random events. ProcessIQ identifies those patterns early.
Start a free diagnostic on your paper machine. Web breaks, press section, dryer section — ProcessIQ covers it all.
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