At Mercer Celgar, employee-driven innovation led to a significant improvement in operational efficiency. This employee-led project tackled inefficiencies in the mill’s unique dual-pulp-machine setup, which caused excessive fiber losses of 4.2 tonnes per day—well above industry norms. Rising fiber and chemical costs made addressing this challenge a priority.
The solution was simple yet effective: decoupling the stock preparation system from machine production rates by stabilizing its flow. This allowed the hydrocyclone cleaning system to operate consistently, reducing fiber losses and enhancing system performance. Key upgrades in automation and process controls supported this approach, which originated from the practical insights of experienced machine room operators.
As a result, fiber losses dropped by 79%, reducing equipment wear, and improving process stability. This collaborative effort showcases the value of listening to frontline workers, fostering teamwork, and driving operational excellence at Mercer Celgar.
