Connecting the pulp and paper Industry: KPNB's role in enhancing efficiency, sustainability, and digital transformation Johannes Holubec, Pixact Product Manager

PAPERTECHNOLOGYINTERNATIONAL
By integrating such IoT technologies, companies cannot
only optimise production but also implement predictive maintenance
strategies that increase long-term efficiency and reduce costs. One
illustrative case is the collaboration between Endiio and Munksjö
Dettingen. Endiio developed a vibration monitoring IoT sensor
platform specifically for predictive maintenance in the paper industry.
Wireless, energy-autonomous sensors were installed at various
production points, particularly to monitor press and guide rolls.
The benefits for Munksjö Dettingen were substantial:
• Early fault detection: Sensors identify anomalies and vibrations early, preventing unplanned downtime.
• Reduced maintenance effort: Precise data eliminates
the need for routine, assumption-based maintenance.
• Easy integration: The system is self-sufficient and
does not require direct IT system integration.
• Lower operational costs: Early detection of problems
like bearing damage or roll fractures significantly
reduces repair costs and production losses.
In practice, the system successfully detected a developing
bearing defect on a drying felt guide roll and a pin break on a wire
guide roll in time, preventing serious production disruptions. These
benefits demonstrate how targeted use of IoT and sensors can
significantly enhance efficiency and profitability in paper production.
NEW KPNB-PARTNER – Brenpower - Smart Factory 360° for
Paper Mills
KPNB has entered into cooperation with Brenpower based
in the UK to enter the German speaking market. Brenpower delivers
next-generation factory intelligence tailored for paper mills, where
energy consumption, steam reliability, and production continuity are
mission-critical.
At the core of its offering is online steam trap monitoring
powered by batteryless and wireless IoT sensors—uniquely
designed for steam-intensive environments like paper production.
These maintenance-free sensors instantly detect leaks, eliminate
energy waste, and improve operational safety with no wiring, no
batteries, and no interruptions to production.
The system collects and compares data across machines,
production lines, and departments to:
• Benchmark energy performance
• Calculate utility cost per ton of paper
•
Identify anomalies and optimise ef昀椀ciency
• Enable predictive maintenance before failures occur
In a recent implementation at a major paper mill,
Brenpower reduced energy losses by over 20%, stabilized
production processes, and enabled full utility transparency—turning
consumption data into strategic advantage. The following is the
complete case study.
The Magical Transformation of Steam: A Paper Mill’s Energy
Efficiency Adventure
How one factory turned invisible losses into measurable
gains with real-time steam monitoring.
The Challenge: Managing the Unseen
In one of Europe’s largest paper mills, steam was
everywhere—circulating through miles of insulated pipelines,
powering massive drying cylinders, and driving the delicate balance
between speed, heat, and quality. Yet, for all its importance, steam
remained unseen.
There was no system in place to measure how much steam
was produced, where it went, or how efficiently it was used. Steam
trap failures went undetected. Fluctuations in steam quality caused
inconsistent roll temperatures, leading to defects in paper thickness
and texture. Energy bills were rising, but there was no clarity on
where the waste was occurring.
For the plant’s operations team, this lack of visibility
meant constant guesswork. Maintenance was reactive rather than
preventive. Efficiency improvements were based on assumptions
rather than data. And the plant manager, after decades of
experience, summed it up in one sentence during a conversation
with our team:
“We produce thousands of tons of paper a month, but we
still don’t know where our steam goes.”
The Solution: Bringing Steam to Light
The turning point came when the
factory implemented Brenpower’s real-time
Steam Trap Monitoring and Steam Quality
Monitoring systems. Wireless and batteryless
IoT sensors were installed across critical
points in the steam network—on traps,
headers, and condensate return lines.
These devices began transmitting
live data on temperature, vibration, and
flow conditions, giving the team immediate
visibility into trap performance and steam
behaviour. Blockages, leaks, and quality
losses that once went unnoticed were now
flagged instantly.
Figure 3: Brenpower Steam Solutions.
But Brenpower goes far beyond steam.
Its Smart Factory 360 platform provides real-time monitoring
and AI-driven analysis of all key utilities—steam, compressed air,
chilled water, boilers—across the entire plant.
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KPNB - again as match-maker – connected Endiio
and Brenpower and combinations of the two
companies software, systems and technology are
possible!

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