Dryer section optimisation

Improve runnability, drying efficiency and production performance

We can achieve considerable improvements in runnability with small actions performed over a short time. At the same time, your energy consumption will decrease. Compared to new investments, grinding, balancing and coating are extremely cost-effective measures and will also improve the quality of your paper.

Performing machining, coating and balancing as an on-site service will reduce your downtime multifold compared to removing the cylinder from the machine. PR Rolls has great capacity for performing machining, coating and balancing simultaneously, shortening your downtime even further. For example, one of our projects involved the machining, coating and balancing of 45 dryers in just 12 days.

PR Rolls provides comprehensive dryer section optimisation services for paper, board and tissue machines. By combining measurement, analysis, vacuum technology, airflow management and mechanical improvements, we help mills improve machine runnability, increase drying efficiency and reduce production disturbances.

The dryer section is one of the most critical areas of a paper machine. Small deficiencies in airflow, vacuum performance, sheet stabilisation or moisture control can lead to web breaks, reduced production speed, uneven drying and increased energy consumption.

Through cooperation with leading technology providers such as Runtech, Bellmer and Andritz, PR Rolls delivers practical optimisation solutions that help customers improve the performance of existing dryer sections without major machine rebuilds.

What is dryer section optimisation?

Dryer section optimisation is the process of improving the operation of the drying section of a paper, board or tissue machine.

The objective is to create stable sheet runnability while maximising drying efficiency and minimising energy consumption.

Optimisation may involve:

• Grinding and/or coating and balancing of dryers
• Vacuum system improvements
• Pocket ventilation systems
• Dryer section stabilisers
• Suction boxes
• Airflow optimisation
• Vacuum roll modifications
• Vacuum roll drilling
• Vacuum roll grinding and coating
• Moisture profile improvements
• Dryer fabric performance improvements
• Web stabilisation solutions
• Process measurements and analysis

When these systems work together effectively, mills can often increase production efficiency while reducing operational problems.

Why is dryer section optimisation important?

The dryer section consumes a significant portion of the total energy used in paper production. At the same time, it is one of the most common sources of runnability problems.

Poor airflow management, inadequate vacuum performance or unstable sheet transfer can cause:

• Web flutter
• Web breaks
• Moisture profile variations
• Sheet instability
• Reduced machine speed
• Increased steam consumption
• Higher energy costs
• Reduced production efficiency

Optimising the dryer section helps create a more stable and predictable production process.

Common dryer section challenges

Frequent web breaks
Unstable sheet transfer between dryer groups often leads to web breaks and production losses.

Improved stabilisation and airflow control help maintain sheet stability throughout the dryer section.

Sheet flutter and instability
High machine speeds create complex airflow conditions that can affect web stability.

Pocket ventilation and stabilisation systems help control air movement around the sheet and improve runnability.

Uneven drying
Poor moisture removal and airflow management can lead to uneven drying profiles.

Optimisation improves drying conditions and supports more consistent product quality.

Excessive energy consumption
Many dryer sections operate with unnecessary energy losses caused by inefficient airflow or vacuum systems.

Modern optimisation solutions can improve energy efficiency while maintaining or improving drying performance.

Limited production speed
In many mills, dryer section limitations prevent speed increases.

Optimisation projects often identify opportunities to improve runnability and support higher production rates.

Complete dryer section optimisation solutions

PR Rolls provides complete optimisation projects ranging from individual improvements to full dryer section assessments.

Dryer section analysis

Every optimisation project starts with understanding the current operating conditions.

PR Rolls together with Runtech evaluates:

• Dryer section performance
• Measurement of geometry
• Airflow conditions
• Vacuum performance
• Web stability
• Moisture behaviour
• Existing equipment
• Production challenges

The goal is to identify the root causes of runnability or efficiency issues.

Pocket ventilation systems

Pocket ventilation is one of the most effective methods for improving drying conditions and web stability.

Proper ventilation removes humid air from dryer pockets and replaces it with controlled airflow.

Benefits include:

• Improved drying efficiency
• Better moisture profiles
• Increased machine stability
• Reduced flutter
• Lower risk of web breaks

PR Rolls works together with technology partners to deliver pocket ventilation solutions tailored to each machine.

Dryer section stabilisers

At higher machine speeds, sheet stabilisation becomes increasingly important.

Dryer section stabilisers help maintain sheet control during open draws and transfer points.

Benefits include:

• Improved web stability
• Reduced sheet flutter
• Fewer web breaks
• Higher machine speeds
• Better runnability

Stabilisation systems can often be installed as part of broader dryer section optimisation projects.

Suction boxes and vacuum solutions

Vacuum technology plays a critical role in sheet control and moisture management.

PR Rolls provides solutions including:

• Suction boxes
• Vacuum equipment
• Vacuum system optimisation
• Vacuum roll modifications
• Vacuum roll drilling

Proper vacuum performance helps improve sheet handling while supporting efficient drying.

Vacuum roll drilling

PR Rolls offers specialised vacuum roll drilling services as part of dryer section optimisation.

Vacuum roll drilling can significantly improve:

• Vacuum performance
• Airflow control
• Water removal
• Web stability
• Dryer section efficiency

Optimised vacuum rolls contribute to a more stable drying process and improved machine performance.

Dryer section modernisation

Many dryer sections contain equipment that was designed decades ago.

Rather than replacing the entire section, targeted modernisation can often provide significant improvements.

Typical modernisation projects include:

• New stabilisers
• Pocket ventilation upgrades
• Vacuum improvements
• Airflow optimisation
• Vacuum roll modifications
• Dryer section measurements

This approach helps mills achieve performance improvements while controlling investment costs.

Benefits of dryer section optimisation

A well-optimised dryer section can provide significant operational and economic benefits.

Improved runnability
Stable sheet transfer reduces disturbances and improves production reliability.

Reduced web breaks
Better sheet control lowers the risk of web breaks and production interruptions.

Higher production efficiency
Optimised drying conditions support stable machine operation and higher production output.

Improved product quality
More consistent drying contributes to improved moisture profiles and product quality.

Lower energy consumption
Efficient airflow and vacuum management help reduce energy losses.

Increased machine speed
Many optimisation projects create opportunities for higher production speeds.

Better return on existing assets
Optimisation allows mills to maximise the performance of existing equipment before considering major rebuilds.

Industries we serve

Paper mills
Improve drying performance, runnability and production efficiency.

Board mills
Support stable operation and moisture control for demanding board grades.

Tissue mills
Enhance Yankee and dryer section performance through improved airflow and stabilisation.

Pulp drying applications
Improve drying efficiency and operational reliability.

Why choose PR Rolls?

PR Rolls combines practical field experience with specialised technology partnerships and on-site service capabilities.

We provide:

• Dryer section optimisation expertise
• Vacuum roll drilling
• On-site machining
• Measuring services
• Coating services
• Balancing services
• Vacuum and airflow optimisation
• Stabilisation solutions
• Cooperation with leading technology suppliers

By combining optimisation technologies with on-site maintenance expertise, PR Rolls can deliver complete solutions that improve both machine performance and long-term reliability.

Typical optimisation project

A typical dryer section optimisation project includes:

1. Assessment
Review current dryer section performance and operating challenges.

2. Measurement
Geometry and condition of existing dryers, analyse airflow, vacuum performance and sheet behaviour.

3. Recommendation
Need of grinding, coating and balancing, stabilisation, ventilation and vacuum improvements.

4. Implementation
Grinding, coating and balancing. Install or modify equipment such as stabilisers, suction boxes or vacuum solutions.

5. Verification
Confirm improvements in runnability, drying performance, doctoring performance and efficiency.

We have solved more than a thousand cylinder problems globally. When you want to optimise your machine’s dryer section within a specific timetable, please ask us for an estimate.

See our video on drilling vacuum rolls and fill in the contact form!