Save steam, starch and energy. Cut your cost per tonne substantially while increasing output and maintaining quality - with real-time process optimization
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Even in stable, well-managed operations, teams often avoid pushing process limits. Not out of reluctance — but because they lack the visibility and confidence to do so safely.
The result: teams can’t operate close to spec limits with confidence — leaving performance and savings on the table.
When paper and board lines aren’t run close to spec limits, the result isn’t just caution — it’s cost. Every shift, every roll, the impact adds up.
The result: avoidable costs in the high six-figure range — and in many cases, €1 million+ per line per year.
Process Booster X (PBX) turns complex process behavior into clear, real-time guidance — helping your team make the right decisions, at the right moment, with confidence.
For paper and board lines, this means eliminating overquality, cutting starch use, and reducing steam consumption — while keeping quality and output rock solid.
On a modern paper line - already equipped with heat recovery and advanced energy management systems - PBX uncovered significant untapped potential in process settings.
Within just a few weeks, PBX achieved a 6% reduction in steam consumption, equivalent to €750,000 per year in savings (site-specific). Material savings through tighter starch control are not yet included in this figure.
How It Was Achieved
PBX optimized the drying section dynamically by matching drying demand to actual process conditions — without any hardware changes or disruptions to production.The result: stable quality, faster stabilization after changes, and less overuse of steam and starch.
PBX brings true intelligence to production — not by adding hardware, but by understanding how your line behaves. It continuously learns, predicts, and acts to keep quality stable and resource use minimal.
PBX learns the real cause–effect relationships of your line directly from raw data — requiring only minimal expert input.
PBX turns live data into real-time actions that increase output and maintain quality while cutting energy and material use.
Start with recommendations for operators; move to automatic execution within guardrails once confidence is built.
PBX directly improves process efficiency and stability — not through new equipment, but by optimizing how existing systems are controlled. The impact becomes visible within weeks of operation.
Substantially lower consumption through improved drying efficiency and precise control of actual drying demand.
Significantly reduced use by minimizing quality safety margins while maintaining reliable quality on spec.
Tighter to spec, faster stabilization after grade changes, fewer excursions, and less broke.
Through these savings, Process Booster X helps reduce annual production costs by high six-figure amounts - up to €1 million per line.
We begin with a discovery call to align on goals and available data. Based on that, we conduct a free preliminary analysis to estimate the potential savings for your specific lines — providing a solid foundation for next steps.
We discuss your production setup and challenges and align on where PBX can create the strongest impact.
You share historical production data (under NDA). We evaluate data coverage and quality, and provide first actionable insights - check out our data requirements.
We share the quantified potential and discuss suitable next steps - pilot, scope, and timeline.
Ready to see what’s possible on your lines?
Request a discovery call with our experts to discuss your potential.