“Close enough” alignment can be a costly assumption. In paper manufacturing machines, minor misalignments often go undetected in critical areas, such as the press, dryer, and wire sections. Even slight deviations can disrupt tension, cause tracking issues, and accelerate wear.
However, detecting these shifts during operation is tricky.
Signs like telescoping rolls, uneven felt stretch, or added bearing stress often only appear after issues have progressed significantly. Such subtle misalignments quietly undermine efficiency, causing excess waste, rising costs, and premature breakdowns.
Even if alignment checks are part of your routine, conventional methods like plumb bobs, optics, and even more advanced tools leave room for error. In the complex, multi-level setups of modern paper machines, these tools simply aren’t precise enough to catch the full picture. Therefore, even though you might think your equipment is aligned, chances are it’s not.
Why Conventional Alignment Methods Just Don’t Cut It
Historically, tools like plumb bobs and optical instruments have been used for alignment, but they come with serious limitations. For example, plumb bobs lack the digital reading and reporting capabilities needed to capture the subtle misalignments that can disrupt performance.
Optical instruments, while more advanced, require a clear line of sight, which isn’t feasible for complex, multi-level roller setups. Their measurements are also vulnerable to factors like temperature, humidity, and technician skill. Most significantly, the alignment process with optical devices demands substantial machine downtime to complete, sometimes stretching into days or even weeks for a full setup.
These methods simply fall short of the accuracy and efficiency needed to keep production on track.
How ParAlign Tackles Misalignment Challenges
This is where ParAlign makes all the difference. Unlike conventional tools, ParAlign uses military-grade ring-laser gyroscope technology, designed specifically to capture alignment data without the need for a clear line of sight; just a reference roll. This enables ParAlign to measure alignment across even the most complex, multi-level setups swiftly, including basement rolls.
For paper mills, this means rapid, accurate alignment data on rolls of all sizes, from Yankee dryers to small lay-on idlers — without the extended downtime that traditional methods require. The ParAlign service team can measure up to 100 rolls in a single appointment with the device, delivering actionable insights on the spot. Instead of shutting down production for days to catch every roll, operators can get comprehensive data and make adjustments during a single shutdown, maximizing uptime.
From new installations to routine maintenance, ParAlign tackles alignment challenges across all critical areas in paper production.
ParAlign in Action: Key Alignment Areas
Press Section
Problem: Misalignment can lead to uneven pressure distribution, causing inefficient water removal and reducing the press’ effectiveness. This imbalance can also accelerate the wear of press fabrics and compromise the sheet’s quality. Additionally, rolls within a felt run need to be level and aligned with the machine baseline for proper felt tracking and alignment of the trade seam.
Results with ParAlign:
- Prolongs the life of wires, felts, and roll covers
- Reduces folds and creases
- Maintains a consistent moisture profile
Drying Section
Problem: Here, felt tracking issues, sheet breaks, and wrinkles can arise from alignment errors, bringing production to a halt. Additionally, equipment components like gearboxes and motors face added strain when misaligned, leading to decreased efficiency and faster wear on couplings and bearings, which can result in premature part failure.
Results with ParAlign:
- Extends the lifespan of fabrics and roll covers
- Reduces the risk of folds
- Ensures a consistent thickness profile
Calendar Section
Problem: In the calendar section, rolls need to be aligned within 0.015” tolerance when nipped to prevent uneven pressure, which creates the “scissoring effect.” This misalignment can lead to folds, paper breaks, and winding inconsistencies, all of which increase waste and stress on bearings and rolls.
Results with ParAlign:
- Reduces paper folds and breaks
- Lowers waste
- Prolongs the life of bearings and rolls
- Delivers uniform winding
With ParAlign’s precision alignment in these key areas, paper mills experience measurable improvements in performance and quality. Here’s one example:
Success Story: ParAlign Solves Tracking Issues for Quebec Paper Mill
A paper mill in Quebec, Canada, turned to the ParAlign service team after encountering persistent tracking issues and product wrinkling during production. In less than 12 hours, a team of Prüftechnik engineers measured all three press sections in a paper machine and worked alongside the plant’s mechanics to perform adjustments on the rolls deemed critical to correct.
The diagram below illustrates the misalignment found in a press section at the plant.
Within weeks after the alignment, the mill reported significant improvements in product quality and noted that the tracking problems had disappeared. They were also pleased with the speed of service as the entire alignment process was completed in a single day — a task that would have required far more time with conventional alignment methods.
ParAlign: Precision When You Need It
The true advantage of ParAlign is not only in its speed and precision but also in the full-service support it offers. With ParAlign, there’s no need for additional equipment purchases or new in-house maintenance plans; instead, your team gains access to cutting-edge alignment technology delivered by a dedicated expert team.
With ParAlign, “close enough” becomes a thing of the past. Your mill gains alignment you can rely on every time.
Click here to learn more about scheduling a ParAlign service for your mill
