PAPER TECHNOLOGY INTERNATIONAL From invisible losses to measurable gains: Why connecting the right technologies matters more than ever. Nicole Buschmeier, Owner, KPNB

PAPERTECHNOLOGYINTERNATIONAL
Turning Energy into a Controlled Variable: Brenpower AI
Energy – particularly steam – remains one of the largest
cost factors in paper production. Yet in many mills, it is still not fully
transparent.
Brenpower AI addresses this challenge with a combination
of wireless, battery-free sensors and AI-based analytics. Their
systems monitor steam valves, steam 昀氀owmeters, steam traps,
detect leakages and analyse energy 昀氀ows across the plant in real
time.
In one implementation, a mill that previously had no detailed
visibility of its steam system was able to identify signi昀椀cant losses
within weeks. Steam trap failures were detected far more quickly,
energy consumption was reduced, and process stability in the drying
section improved noticeably.
Perhaps most importantly, decisions could now be based on
data rather than assumptions. Steam, once an invisible and largely
unmanaged resource, became a measurable and controllable part of
the production process.
What makes it unique is the non-invasive real-time
measurement of mass 昀氀ow, steam dryness and recommendations
for action depending on the monitored instruments’ performance.
Predictive maintenance at the right valve, the right steam trap or
昀氀owmeter saves time and steam or
condensate losses.
The installation of Brenpower
sensors is scalable. For example,
the steam sensor is always the same
size independent of the pipe diameter
where you want to measure.
To have a look at the easy-toinstall sensors use this QR code:
Reliability in the Details: Lanex Paper Machine Ropes
Not all optimisation requires digital solutions. In many cases,
improvements come from rethinking components that are often
taken for granted.
Lanex focuses on high-performance paper machine ropes,
a small but critical element in ensuring smooth operation. Rope
failures can lead to unplanned stoppages, increased maintenance
effort and safety risks.
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Image 8: Long-lasting ropes for better and reliable
runnability.
In a coating application, a mill struggling with short rope
lifetimes tested an alternative design from Lanex. The result was a
signi昀椀cant increase in service life, reducing the frequency of rope
changes and improving overall machine availability.
Such examples demonstrate that even seemingly minor
components can have a substantial impact when optimised correctly.
In 2025 a board mill in Germany tested Lanex ropes
successfully in the drying section. The customer has a production
of >400.000 t/y with liner and board between 150 and 350 gsm. The
ropes used were Superline DUO with core. During the test they were
running without issue for about 10 weeks. The quality check done
afterwards in the Lanex laboratory showed an expected remaining
lifetime of 70%. That means under normal production conditions new
ropes are able to last over 30 weeks.

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